Rytec System 4 Owner's/Installation Manual

System 4® Drive & Control RY-WITM SYSTEM RYTEC HIGH PERFORMANCE WIRELESS TECHNOLOGY

Installation & Owner’s Manual

[Revision: September 11, 2015, 00152000, ©Rytec Corporation, 2011]

TABLE OF CONTENTS

PAGE INTRODUCTION...... 1 DOOR SERIAL NUMBER(S)...... 1

HOW TO USE MANUAL ...... 2

REQUIRED TOOLS AND EQUIPMENT ...... 2

ADDITIONAL REQUIREMENTS...... 2

Labor and Site Requirements...... 2 Electrician’s Responsibilities...... 2 SHIPPING CRATE...... 2

SYSTEM OVERVIEW ...... 2 CONTROL PANEL...... 2

INSTALLATION ...... 4 CONTROL PANEL INSTALLATION ...... 4

CONTROLLER ...... 8

Scrolling Display ...... 8 USB Connector ...... 8 Status LEDs ...... 8 Plug-In Modules...... 8 SYSTEM INPUTS ...... 9

Power Supply Lines...... 10 Motor...... 10 Motor Brake ...... 10 Encoder ...... 10 External Emergency Stop Switches (N.C. Contacts) ...... 10 Breakaway Bottom Bar (Input 1 — N.C. Contact)...... 10 Automatic Photo Eye Circuit Testing...... 10 Photo Eye — Front (Input 2 — N.C. Contact) ...... 10 Photo Eye — Rear (Input 3 — N.C. Contact) ...... 11 Alternate-Action Activator (Input 4 — N.O. Contact) ...... 11 Auto-Close Activator 1 (Input 5 — N.O. Contact) ...... 11 Auto-Close Activator 2 (Input 6 — N.O. Contact) ...... 11 Open (Input 8 — N.O. Contact)...... 11 Close (Input 9 — N.O. Contact) ...... 11 Stop (Input 10 — N.C. Contact) ...... 12 Programmable (Inputs 11 and 12 — N.O. or N.C. Contact) ...... 12 DC Power Supply — Photo Eyes ...... 12 DC Power Supply — Auxiliary Device ...... 12 Reversing Edge ...... 12 Timers...... 13 SYSTEM START-UP...... 13 MODES OF OPERATION ...... 13

Run Mode ...... 13 AUTOMATIC MODE ...... 13 NON-AUTOMATIC MODE...... 14 Jog Mode ...... 14 Parameter Mode...... 14 Display ...... 14 SYSTEM CONTROLS ...... 14

SERVICE LEVELS ...... 14

INITIAL START-UP ...... 15

Clock Setting Procedure...... 16 ACCESSING PARAMETERS ...... 16

Parameter Messages...... 16 Navigating Parameters ...... 17 Accessing Service Level 2 ...... 18 Setting Door Limits (Open, Intermediate, and Close) ...... 18 Setting Automatic Delay Timers...... 18 SYSTEM RESET (MANUAL RESET) ...... 19

DEFROST SYSTEM ...... 19

WIRELESS REVERSING EDGE...... 19

Parameters for Wireless System ...... 20 SYSTEM PARAMETERS ...... 26 OPERATOR LEVEL PARAMETERS...... 26

SERVICE LEVEL 2 PARAMETERS ...... 27

CLOCK PARAMETERS ...... 34 FAULT CODES ...... 35

GENERAL OPERATION FAULT CODES ...... 35

DOOR SAFETY/EMERGENCY FAULT CODES ...... 38

REVERSING EDGE CIRCUIT FAULT CODES ...... 39

DRIVE SYSTEM FAULT CODES (400-LEVEL CODES)...... 41

DRIVE SYSTEM FAULT CODES (500-LEVEL CODES)...... 42

DOOR POSITION FAULT CODES ...... 44

WIRELESS SYSTEM FAULT CODES...... 46

DELAY TIMERS...... 51

MISCELLANEOUS MESSAGES ...... 51 DOOR MESSAGES ...... 51

SPECIAL STATUS MESSAGES ...... 51

DOOR LIMIT MESSAGES...... 51

DOOR JOG MESSAGES ...... 52

DOOR STATUS MESSAGES ...... 52

PROGRAMMABLE TEXT MESSAGES ...... 55

TROUBLESHOOTING ...... 56 TROUBLESHOOTING WITH STATUS LEDS ...... 56

SPECIFICATIONS ...... 57 MECHANICAL...... 57

INPUTS ...... 58

OUTPUTS ...... 59

PLUG-IN MODULES (OPTIONAL ITEMS) ...... 60

ABBREVIATIONS ...... 60

SCHEMATICS...... 61 GENERAL — INCOMING POWER ...... 61

GENERAL — ENCODER AND PHOTO EYES ...... 62

GENERAL — RADIO CONTROL AND E-STOP...... 63

GENERAL — BOTTOM BAR CONNECTIONS ...... 64

GENERAL — CONTROLLER DIMENSIONS ...... 65 PARTS LIST ...... 66 PARTS ORDERING INFORMATION...... 66

How to Order Parts ...... 66 SERIAL NUMBER(S) ...... 66

Substitute Parts ...... 66 Return of Parts...... 66 CONTROL PANEL — STANDARD PANEL ...... 67 INTRODUCTION—DOOR SERIAL NUMBER(S)

INTRODUCTION NOTE: Figure 2 shows a sample decal. Different model doors have serial numbers that NOTE: This manual is intended for the System 4 start with different numerals. Drive & Control only. Installation and operation information specific to your door is detailed in the installation and owner’s Head Assembly manuals that were shipped with the door. (Includes Drive Motor) Rytec The installation and operation of the System 4 Drive & System 4 ® Control is not difficult, providing you follow the proce- Control Panel dures outlined in this manual. Any unauthorized changes to these procedures, or failure to follow the steps as outlined, will automatically void our warranty. Any changes to the working parts, assemblies, or specifications as written, not authorized by Rytec Corpora- tion, will also cancel our warranty. The responsibility for the successful operation and performance of this drive and control system lies with the owner of the door. DO NOT INSTALL, OPERATE, OR PERFORM MAIN- TENANCE ON THIS DRIVE AND CONTROL SYSTEM UNTIL YOU READ AND UNDERSTAND THE INSTRUCTIONS IN THIS MANUAL. Left Side Column If you have any questions, contact your Rytec represen- (Includes Counterweight tative or call the Rytec Technical Support Department at and Left Front and Rear 800-628-1909. Always refer to the serial number of the Photo Eyes) door that your control system is connected to when call- ing the representative or Technical Support. Refer to the Right Side Column installation manual or the owner’s manual provided with (Includes Counterweight your door for the location of the serial number plate. and Right Front and Rear A2500264 Photo Eyes) The wiring connections and schematics in this manual are for general information purposes only. A wiring Figure 1 schematic is provided with each individual door, specif- ically covering the control panel and electrical components of that door. That schematic was shipped inside the cardboard box containing the control panel. DOOR SERIAL NUMBER(S) Yo u r DOOR SERIAL NUMBER information can be found in three universal locations. These are at the inside of either side column (approximately eye level), on the drive motor, and on the inside door of the System 4 control panel. (See Figure 1.)

IMPORTANT: When installing multiple doors of the same model but in different sizes, verify the serial number in the control panel with the one on the door assembly. A5400013 Figure 2

1 SYSTEM OVERVIEW—HOW TO USE MANUAL

HOW TO USE MANUAL NOTE: High- and low-voltage cables must be routed in separate conduit. High voltage Throughout this manual, the following key words are must use metallic conduit. used to alert the reader of potentially hazardous situations, or situations where additional information to suc- 4. Run electrical power lines to fused disconnect. cessfully perform the procedure is presented: 5. Run power lines from disconnect to control panel. 6. Run power and control lines from control panel to door head assembly (and defrost system, if used). 7. Install conduit from control panel to floor for floor WARNING is used to indicate the potential loop activators and wire activators, if used. for personal injury, if the procedure is not performed as described. 8. All cables must be cut to length. No excess of high- or low-voltage cables should be present in the control panel. SHIPPING CRATE The control panel was shipped from the factory in a card- CAUTION is used to indicate the potential board box along with the contents of your Rytec door. for damage to the product or property damage, if the procedure is not followed NOTE: A door-specific electrical schematic is as described. located inside the control panel.

IMPORTANT: IMPORTANT is used to relay infor- SYSTEM OVERVIEW mation CRITICAL to the successful completion of the procedure. CONTROL PANEL NOTE: NOTE is used to provide additional infor- The Rytec System 4 Drive & Control is a solid-state, mation to aid in the performance of the microprocessor-based control system designed exclu- procedure or operation of the door, but not sively to operate your Rytec high-performance door. necessarily safety related. (See IMPORTANT below.) It combines an AC drive with the latest in door control technology. REQUIRED TOOLS AND EQUIPMENT The AC drive system controls the drive motor through 1. Wall anchor hardware (¹₄-in. diameter). soft accelerations and soft decelerations. The operating ▲ 2. Carpenter’s level. parameters are accessed through the up ( ), down (▼), and reset (●) keys located on the keypad on the 3. Hammer drill and masonry drill bit sized for wall front of the control panel. A scrolling display shows all anchors (to install anchor hardware in concrete). corresponding control and door status messages. 4. Assorted hand tools. NOTE: The RESET key also serves as the ENTER ADDITIONAL REQUIREMENTS key and the STOP key. Labor and Site Requirements IMPORTANT: The System 4 control panel 1. An electrician is required for all electrical connec- allows for configurable supply tions. (See “Electrician’s Responsibilities” below.) voltage. Voltages can range from 200–500 volts AC. The System 4 IMPORTANT: All electrical work must be per- can also be configured to formed in accordance with local receive both single- and three- and state building codes. phase voltages. The supply voltage MUST match the voltage and 2. 100% accessibility to the door opening during the phase as listed on the electrical installation process. Traffic should not pass through schematic provided with the the opening during the installation procedure. control panel. Failure to provide Electrician’s Responsibilities the required voltage and phase may damage the controller. If 1. Furnish and install fused disconnect(s). voltage and phase do not match 2. Install Rytec control panel. supply, contact the Rytec Tech- nical Support Department at 800- 3. Install all necessary conduit. 628-1909.

2 SYSTEM OVERVIEW—CONTROL PANEL

A5400011 Figure 3

IMPORTANT: All conduit entering the control panel must enter from the bottom of the panel — high voltage from the bottom left and low voltage from the bottom right. Installing conduit through the top or sides of the control panel will void the warranty.

3 INSTALLATION—CONTROL PANEL INSTALLATION

INSTALLATION Head Assembly CONTROL PANEL INSTALLATION (Includes Drive Motor) Rytec IMPORTANT: The control panel must be System 4 installed in an area having a tem- Control Panel perature range of –4°F to 149°F. If the temperatures approach these limits, contact the Rytec Technical Support Department at 800-628-1909.

The fused disconnect and the control panel must be installed within sight of the door.

NOTE: The control panel and fused disconnect are generally located adjacent to the drive end of the head assembly. Left Side Column (Includes Counterweight Install the System 4 control panel and the fused discon- and Left Front and Rear nect as shown in Figure 4. The System 4 control panel has Photo Eyes) three mounting locations on the black plastic enclosure. One is at the top of the enclosure in the center, and two are Right Side Column at the bottom of the enclosure. (See Figure 5.) Use these (Includes Counterweight mounting locations along with user-supplied hardware to and Right Front and Rear securely mount the panel at the chosen location. Photo Eyes) A2500264 IMPORTANT: The mounting surface must be structurally sound and free of Figure 4 mechanical shock or vibration. All conduit entering the control NOTE: Panel housing shown disassembled for clarity. panel must enter from the bottom of the panel — high voltage from the bottom left and low volt- Top Mount age from the bottom right. Installing conduit through the top or sides of the control panel will void the warranty.

Bottom Mounts

A5400020

Figure 5

4 INSTALLATION—CONTROL PANEL INSTALLATION

The System 4 panel door is hinged at the top for easy access to the terminal blocks. To open the door, loosen the six screws along the door face as shown in Figure 6 and lift the door slightly out to release screws. Then lift Electrical the door up as shown in Figure 7. The door can be Door Hinge Harness removed from the controller by disconnecting the door electrical harness and depressing the tabs at the top of the controller to release the hinges from the controller body as shown in Figure 8.

A5400037

Figure 8

Mounting Screw Grounding of the power supply is essen- tial to the safety of personnel as well as the operation of the System 4 Drive & Control. A floating, ungrounded or open delta type power supply can permit dangerously high voltage between the chassis of the A5400033 drive and the internal power structure Figure 6 components. (See Figure 9.) In many cases, this voltage could exceed the rating of the input MOV protection devices of the drive, causing catastrophic failure of the System 4 Drive & Control. In all cases, the input power to this controller must be referenced to ground. (See Figure 10.) If the service transformer cannot be grounded, an isolation transformer must be installed with the secondary of the transformer grounded. Please consult the factory for additional information regarding isolation transformers or service suitability.

A5400035 Figure 7

5 INSTALLATION—CONTROL PANEL INSTALLATION

NOTE: All wiring from the fused disconnect to the control panel, from the control panel to the optional junction box and the door, and from the conduit between the control panel and the floor (if a floor loop is used) must be supplied by the door owner. The wiring and conduit must meet all local and state building codes. Wires leading from the door are labeled with the terminal numbers that are associated with the control panel. The high and low voltage lines must run in separate conduit — otherwise, the warranty will be void.

Use shielded wire as indicated on the schematic. If a wire cable is to be extended or A5500019 spliced, a like cable must be used throughout the entire length of that cable. Likewise, if a Figure 9 shielded cable is to be extended or spliced, a NOTE: Cables must be cut to length. There can- like cable must be used throughout the entire not be any excess cable present in the length of that cable as well — otherwise, the control panel or any excessive cable bun- warranty will be void. dles present on the outside of the control panel. IMPORTANT: All conduit entering the control panel must enter from the bottom of the panel — high voltage from the bottom left and low voltage from the bottom right. Installing conduit through the top or sides of the control panel will void the warranty.

The System 4 panel conduit connection locations are NOT knock- outs. Do NOT use impact to remove the conduit connection bosses, or damage to the panel housing can occur. A drill and suitable drill bit should be used to remove the plastic for conduit connection. (See Figure 11.)

A5500020

Figure 10

A5400021

Figure 11

6 INSTALLATION—CONTROL PANEL INSTALLATION

IMPORTANT: If your door is to be mounted on You must wait at least five minutes after a freezer, mount the control power is turned off before you can begin panel and the fused disconnect work on the control panel or motor con- on the warm side of the wall. It nections. The drive control inside the may also be necessary for you to panel contains high-voltage capacitors, install more than one fused dis- which take time to discharge once power connect. To ensure the equip- is turned off. ment is de-energized during A small cardboard box has been shipped with the con- maintenance or service, turn off trol panel. This box contains five ferrite core filters. all disconnects. These ferrite core filters are to be installed on the incoming L1, L2, and L3 supply voltage wires and also on the Protect the components inside T1, T2, and T3 motor connections. The ferrite core fil- the control panel from metal ters act as a filter for the incoming supply power and chips when installing conduit. voltage passing to the motor. These filters help to Seal inside the conduit and reduce electrical noise in the power system. See Figure panel if the conduit entering the 12 for proper installation of the ferrite core filters. panel is coming from an area having a different temperature NOTE: Failure to install the ferrite core filters as (warmer or colder) than the area illustrated will void the manufacturer’s war- where the panel is located. ranty.

The schematics shown throughout this manual are for information purposes only. Due to varying requirements of each Failure to install the ferrite core filters will customer, a schematic has been void the manufacturer’s warranty and prepared for your particular door potentially cause irreparable damage to and it must be used for this the System 4 control panel. installation. That schematic was shipped inside the control panel.

The disconnect must be in the OFF position and properly locked and tagged before wiring of the control panel begins. Supply Voltage IMPORTANT: All conduit entering the control Filter Location panel must enter from the bottom of the panel — high voltage from the bottom left and low voltage from the bottom right. Motor Connection Green Installing conduit through the Filter Location Ground Wire top or sides of the control panel A5400029, A5400030 will void the warranty. Figure 12 NOTE: It is not necessary to run the supply voltage ground wire (green wire) through the ferrite core filter. High voltage is present inside this control panel. Do not touch the circuit board, electrical components, or wiring inside this panel with power applied.

7 INSTALLATION—CONTROLLER

CONTROLLER Status LEDs Located inside the control panel is an electronic control- Located on the controller are various light-emitting ler. This controller includes a scrolling display, terminal diodes (LEDs). These diodes are helpful when trouble- blocks and screws, and other miscellaneous electrical shooting the door and control system. The LEDs indi- components. (See Figure 13.) cate the operating status of the control system, the door, activators, safety devices, and any other input device connected to the control system. (See Figure 14.)

USB Connector For detailed information on troubleshooting the control Scrolling system using the status LEDs, see “TROUBLESHOOT- Display ING WITH STATUS LEDS” on page 56.

Battery

Service Switch 24 V Short LED

Green Reversing Terminal Terminal Block(s) Red Edge LEDs Screws Run LEDs (Green)

Ajar LED

A5400016 Figure 13

Scrolling Display Input LEDs All door commands and door status messages appear A5400016 on the scrolling display. Also displayed are the cycle counter, timer settings, alarm conditions, program set- Figure 14 tings, and other miscellaneous messages. Plug-In Modules The display is located near the top of the controller and For a door set up to be operated by a radio control or a can be viewed through the window on the front of the floor loop, a corresponding plug-in module for each type control panel. (See Figure 13.) of activator is required. The connectors for these mod- USB Connector ules are located along the right edge of the lower printed circuit board. (See Figure 15.) The USB drive logs the function of the door and allows for programming the door using a Rytec encrypted software program. Removing the USB drive will affect the operation of the door. DO NOT remove the USB drive unless informed by the Rytec Technical Support Depart- ment to do so.

8 INSTALLATION—SYSTEM INPUTS

SYSTEM INPUTS

The disconnect must be in the OFF posi- Radio Receiver tion and properly locked and tagged before Module performing the following procedure.

Input terminals 200 through 293 support +24 VDC only. All remaining input termi- Induction Loop nals are dedicated for specific devices. Module Connecting any other voltage or device other than those intended may result in damage to the control system.

NOTE: If the expansion board is installed in the controller, there are additional input terminals 300 through 363.

All high-voltage connections (L1, L2, and L3 supply voltage wires and T1, T2, and T3 motor connections) are A5400016 made on the lower left terminal blocks. These connec- Figure 15 tions need to be in metallic conduit entering from the bottom left corner of the control panel. All low-voltage NOTE: The induction loop module for the System connections (+24 VDC) should enter the bottom right 4 (part #00122000) is different from the corner of the control panel and terminate on both the module for the System 3. The System 4 top and bottom circuit boards. (See Figure 17.) module is physically smaller. Therefore, the System 3 loop module will not fit in the System 4 control. (See Figure 16.)

Loop Wire Terminal Block

Ter minal Terminal Block(s) Screws

A5400016

Figure 17

A5400024 Figure 16

9 INSTALLATION—SYSTEM INPUTS

Power Supply Lines Breakaway Bottom Bar (Input 1 — N.C. Contact) Connect the power supply lines from the fused disconnect The breakaway bottom bar signal is incorporated with to the control panel as shown on the schematic that was the Ry-Wi wireless reversing edge signal. The break- shipped with the door. away electrical connections are connected to terminals 5 and 6 on the Ry-Wi mobile unit in the bottom bar. That IMPORTANT: High voltage power supply lines signal is then transmitted from the mobile unit to the need to be installed and routed antenna located on the head assembly of the door. The through metallic conduit. antenna then sends the breakaway signal down the red wire (encoder cable) to terminal 271 in the controller. Motor See the schematic that was shipped with the door. Connect the motor wires to the control panel as shown If the bottom bar becomes disconnected from either on the schematic that was shipped with the door. side column, a loss of this input will immediately stop IMPORTANT: Install and route all motor wires the door and “Door Ajar” will appear on the display. through a metallic conduit. (See Figure 18.)

NOTE: Motor cable cannot exceed 100 ft. Cut all excess cable to desired length. Reference the electrical schematic that came inside Errorly Jog O n the control panel for proper grounding. F060 D oaro r A j

Motor Brake Connect the motor brake to the control panel as shown Figure 18 on the schematic that was shipped with the door. NOTE: If you find it necessary to reposition the NOTE: The motor brake connection is a class 2 bottom bar in order to reattach it, the door circuit (+24VDC) and must NOT be can be jogged up or down by pressing and installed in conduit with any voltages holding the up (▲) or down (▼) key. exceeding +24VDC. Brake wires can be installed with other +24VDC devices, i.e., Push and hold the Stop, Reset and Enter photo eyes, motion detector. buttons until the system resets.

Encoder Once the bar is reattached and the control system reset, the up (▲), down (▼), and Connect the encoder to the control panel as shown on reset (●) keys will automatically return to the schematic that was shipped with the door. their normal operation. NOTE: The encoder connection is a class 2 circuit (+24VDC) and must NOT be installed in Automatic Photo Eye Circuit Testing conduit with any voltages exceeding The System 4 controller initiates an automatic test of the +24VDC. Encoder cable can be installed photo eye circuits each time the door opens. This test with other +24VDC devices, i.e., photo ensures both the front and rear photo eyes are function- eyes, motion detector. ing properly before the door begins to close. This test is performed on the front emitter terminal 221 and terminal External Emergency Stop Switches (N.C. Contacts) 231 for the rear emitter. Due to the test that is performed Factory-installed jumper wires are provided in the E- on the photo eye circuit during each open cycle, it's Stop connections. Refer to the door-specific electrical important that no other wire connections are installed in schematic for information regarding E-Stop connection. either terminal 221 or 231. E-Stop 1 terminals are located at block X24, terminals NOTE: Additional wires in these two terminals will 240 and 241. E-Stop 2 terminals are at block X25, ter- not allow the test to be performed and the minals 250 and 251. E-Stop 3 terminals are at block door will remain open. X26, terminals 260 and 261. Photo Eye — Front (Input 2 — N.C. Contact) Connect the front set of photo eyes to the control panel (terminal 222 located on block X22) as shown on the schematic that was shipped with the door.

10 INSTALLATION—SYSTEM INPUTS

An interruption of this input (object between photo eyes) Auto-Close Activator 1 (Input 5 — N.O. Contact) while the door is closing will reverse the door and move Connect auto-close activator 1 to the control panel (ter- it to the open position. Only after the object is removed minals 210 and 212) as shown on the schematic that from between the photo eyes will the door be allowed to was shipped with the door. close. If this input is enabled with the door closed, closing, or If the door was initially opened by a non-automatic stopped between the door limits, the door will open. The activator, the door must be closed with a non-automatic door will remain open as long as the input is enabled. activator. If the door was initially opened by an auto- Once the input is disabled, the auto-close delay timer matic activator, the door will automatically close after (ACL1) will start. When the timer times out, the door will the auto-close delay timer (ACL1 or ACL2) times out. automatically close. (See Figure 19.) An activated timer will automatically reset when the auto input is enabled. To disable a timer, set its time delay parameter to zero (0) seconds. Parameter P:010 = 0 to turn timer off. DnooreldH O pe Typical activators tied to this input include floor loops Peh o t o e y F r 222 and motion detectors. (This input is exclusive of the inputs described in “Plug-In Modules” on page 8.)

Figure 19 Auto-Close Activator 2 (Input 6 — N.O. Contact) Connect auto-close activator 2 to the control panel (ter- Photo Eye — Rear (Input 3 — N.C. Contact) minals 230 and 233) as shown on the schematic that Connect the rear set of photo eyes to the control panel was shipped with the door. (terminal 232 located on block X23) as shown on the If this input is enabled with the door closed, closing, or schematic that was shipped with the door. stopped between the door limits, the door will open. The An interruption of this input (object between photo eyes) door will remain open as long as the input is enabled. while the door is closing will reverse the door and move it Once the input is disabled, the auto-close delay timer to the open position. Only after the object is removed from (ACL2) will start. When the timer times out, the door will between the photo eyes will the door be allowed to close. automatically close. If the door was initially opened by a non-automatic An activated timer will automatically reset when the auto activator, the door must be closed with a non-automatic input is enabled. To disable a timer, set its time delay activator. If the door was initially opened by an auto- parameter to zero (0) seconds. Parameter P:015 = 0 to matic activator, the door will automatically close after turn timer off. the auto-close delay timer (ACL1 or ACL2) times out. Typical activators tied to this input include floor loops (See Figure 20.) and motion detectors. (This input is exclusive of the inputs described in “Plug-In Modules” on page 8.) Open (Input 8 — N.O. Contact) DnooreldH O pe Connect the open input to the control panel (terminals Peh o t o e y R r 232 200 and 201) as shown on the schematic that was shipped with the door. If this input is enabled (momentary contact) with the Figure 20 door closed, closing, or stopped between the door lim- Alternate-Action Activator (Input 4 — N.O. Contact) its, the door will open. This input is ignored while the door is opening. Connect the alternate-action activator to the control panel (terminals 210 and 211) as shown on the sche- Close (Input 9 — N.O. Contact) matic that was shipped with the door. Connect the close input to the control panel (terminals If this input is enabled (momentary contact) with the 200 and 202) as shown on the schematic that was door closed, closing, or stopped between the door lim- shipped with the door. If this input is enabled (momen- its, the door will open. When this input is enabled with tary contact), the door will close if the door is open or the door open, the door will close. Typical activators tied stopped. This input is disabled when the door is closing to this input include pull cords, push buttons, and radio and ignored if the door is closed or opening. controls.

11 INSTALLATION—SYSTEM INPUTS

Stop (Input 10 — N.C. Contact) The DC power +24 and –24 VDC (GND) can be found at various locations through- Input 10 is equipped with a factory-installed jumper. out the System 4 control board. For exam- Refer to door-specific electrical schematics for informa- ple, terminals 200, 210, 220, 230, 270, tion regarding this connection. 277, and 290 on the microcontroller board Programmable are all access points for +24 VDC connec- (Inputs 11 and 12 — N.O. or N.C. Contact) tion(s). Programmable inputs (if used) are connected to the con- The front set of photo eyes is connected to trol panel (terminals 290 and 291 or terminals 290 and terminal block X22. The +24 VDC is on ter- 292) as shown on the schematic that was shipped with minal 220, the –24 VDC is on terminal the door. These inputs can be assigned various functions 223, and the signal wire connects to termi- such as a third set of photo eyes or an air lock activator. nal 222. DC Power Supply — Photo Eyes The rear set of photo eyes is connected to Connect the 24 VDC power supply for the photo eyes to terminal block X23. The +24 VDC is on ter- the control panel as shown on the schematic that was minal 230, the –24 VDC is on terminal shipped with the door. 234, and the signal wire connects to termi- NOTE: Reference the electrical schematic that nal 232. was provided inside the System 4 control panel. The instructions in this manual per- The photo eye power supply is a dedicated tain to most doors; however, your door power supply for the photo eyes. Each set may have different requirements. of photo eyes should be connected to the specific power supply for that particular set The DC power +24 and –24 VDC (GND) of photo eyes. NO other electrical devices can be found at various locations through- should be connected to the photo eye out the System 4 control board. For exam- power supplies. ple, the front set of photo eyes is connected to terminal block X22. The +24 Reversing Edge VDC is on terminal 220, the –24 VDC is on Anytime the door is closing and the reversing edge (bot- terminal 223, and the signal wire connects tom edge) of the door makes contact with an object, the to terminal 222. door will reverse direction and move to the open position. The door will remain in the open position until the The rear set of photo eyes is connected to control system is manually reset. terminal block X23. The +24 VDC is on terminal 230, the –24 VDC is on terminal 234, To ensure the reversing edge wiring has continuity, the and the signal wire connects to terminal 232. control system monitors a resistor installed on the pressure switch located in the bottom bar. If the control sys- The photo eye power supply is a dedicated tem does not detect the correct resistance, the control power supply for the photo eyes. Each set system will not allow the door to close. of photo eyes should be connected to the NOTE: The reversing edge signal is carried on the specific power supply for that particular set pink wire in the encoder cable. The pink of photo eyes. NO other electrical devices wire is attached to terminal 272 on termi- should be connected to the photo eye nal block X27. power supplies. The reversing edge wires are connected DC Power Supply — Auxiliary Device to the Rytec Ry-Wi mobile unit installed in Connect the 24 VDC power supply for an auxiliary the bottom bar. If you remove the Ry-Wi device (such as a motion detector) to the control panel cover, you will find the reversing edge con- as shown on the schematic that was shipped with the nections on terminals 1 and 2 of the door. mobile unit. A resistance check performed NOTE: Reference the electrical schematic that on these two terminals should read 8,200 was provided inside the System 4 control ohms or 8.2K ohms. If the resistance value panel. The instructions in this manual per- is not found, one of the wires is broken or tain to most doors; however, your door the resistor is bad. may have different requirements.

12 SYSTEM START-UP—MODES OF OPERATION

NOTE: Reference your door-specific electrical schematic for reversing edge connections. These connections may be different for different models of doors. The control panel door must always be IMPORTANT: After control system start-up, closed every time the control panel is pow- test the reversing edge accord- ered up. There is a potential for serious ing to the instructions provided personal injury in the case of component in the owner’s manual that came failure. with the door. You must verify The System 4 Drive & Control is configured for three that the bottom bar reversing modes of operation: run, jog, and parameter mode. edge operates properly before placing the door into service. Run Mode Run mode includes the automatic and non-automatic Timers modes of operation. The control system includes three programmable auto- AUTOMATIC MODE close delay timers. Each timer is assigned to a specific input on the control panel and is set to delay closing the If a momentary contact activator such as a push button, door when opened by its associated activator. pull cord, or radio control is used to activate the door: Two timers (ACL1 and ACL2) can be programmed to • The door will open when the device is activated. automatically close the door from the open position. The • A timer, internal to the control system, will start up third timer (ACL3) can be programmed to close the door when the door is open. from the optional passage position. (The optional pas- • When the internal timer times out, the door will sage position is reserved for setting the open position of automatically begin to close. the door to a height other than the open position.) If a maintained contact activator device such as a floor See “SYSTEM PARAMETERS” on page 26 for addi- loop or motion detector is used to activate the door: tional information on setting the auto-close delay timers and the optional passage option. • The door will open and remain open for as long as the device is active. SYSTEM START-UP • Once the device becomes inactive, the internal timer will start up. MODES OF OPERATION • When the internal timer times out, the door will automatically begin to close. In the automatic mode, while the timer is running, anytime an activator such as a floor loop or motion detector Once electrical power is connected to the is enabled, the timer will reset and the door will not be control system, the fused disconnect must allowed to close. It is only when the timer times out that be placed in the OFF position and properly the door will begin to close. (To change the timer setting, locked and tagged before the door to the see “SYSTEM PARAMETERS” on page 26.) control panel can be opened. In summary, in the automatic mode, an activator is used Once the fused disconnect is placed in the to open the door and a timer is used to close the door. OFF position, you must wait five minutes NOTE: If an activator or photo eyes remain active for all electricity to dissipate from the con- this will hold the door open. Pushing and trol panel — otherwise, severe electrical holding the down arrow will override these shock resulting in serious injury or even signals and allow you to close the door death may occur. manually with the down arrow. If the signal is from an activator the door will re-open until the activator problem is resolved. The door will not re-open if the photo eye is the problem. Safety photo eyes do not open the door. However, they will hold open a door if photo eyes are out of alignment or damaged.

13 SYSTEM START-UP—SYSTEM CONTROLS

NON-AUTOMATIC MODE If a momentary contact activator such as a push button, pull cord, or radio control is used to operate the door: DnooreldH O pe • The door will open when the device is activated. Peh o t o e y F r 222 • A similar type of device must be used to close the door. Figure 22 In summary, in the non-automatic mode, an activator is used to open and close the door. NOTE: If a system error is detected, the status of the door and the associated fault code will Jog Mode appear on the display. (See Figure 23.) Jog mode can be set by pushing and holding the Stop/ Reset key and the down key at the same time until the Door Operated through display reads “Jog Mode”. The door can then only be Up/Down Keys Only operated from the control panel using the up, down, and stop keys. ▲ Eyrror- Jog ▼ O nl To exit jog mode, repeat the process of pushing and For0 6A0 D o jar holding the Stop/Reset and down keys at the same time until the display reads “Automatic”. Fault Code Associated Parameter Mode Problem The control system includes various parameters that Figure 23 are used to operate your door. A number of parameters SYSTEM CONTROLS are set at the factory. Other parameters must be set in the field. All door commands and control system menus are accessed through the control panel keypad. The keypad The “SYSTEM PARAMETERS” on page 26, are orga- includes three keys: up (▲), down (▼), and reset (●). nized according to the Operator/Service Level authorized to access each parameter. Table 5 lists the During normal operation with the door closing or closed, parameters available at the Operator Level. Table 6 lists momentarily pressing the up (▲) key will automatically the parameters available at Service Level 2. move the door to the open position. Pressing the down (▼) key will move the door to the closed position. Press- Display ing the reset (●) key as the door is moving in either The scrolling display shows all door status and system direction will immediately stop the door. information messages. Figure 21 through Figure 23 NOTE: The RESET key also serves as the detail information typically displayed during routine con- ENTER key and the STOP key. troller functions and system errors. SERVICE LEVELS Status Line In addition to operating the door, the up (▲), down (▼), and reset (●) keys are used to navigate through the control system parameters. See “Navigating Parame- ters” on page 17. NOTE: The RESET key also serves as the Information Line — Activated Inputs, ENTER key and the STOP key. Errors, Failures, Etc. The “SYSTEM PARAMETERS” on page 26 are grouped into two service levels. Figure 21 • Operator Level — password not required. Access NOTE: If the photo eyes are activated during a limited to auto-close timers and select defrost con- door close cycle, the door will move to the trol functions (if configured with defrost control). open position and the display will indicate which set of eyes is activated. (See Figure 22.)

14 SYSTEM START-UP—INITIAL START-UP

• Service Level 2 — password required (password is the number 10). Access to Service Level 1 parameters as described above, activator parameters, and other miscellaneous parameters. All remaining !SetLimi ts ! parameters are available as read-only. → ● To Beg in NOTE: The control counts in hexadecimal. When entering the number 10, you will see letters appear after the number 9. When you continue past the letter F, the number 10 Figure 24 will display.

The service switch in the control box is factory set to the ON position. This allows access to all password levels. Access to all parameters can be disabled by placing the The door open and door close limits are to service switch to the OFF position and locking the con- be set only after verifying that the motor trol panel door. Cycling power off and on places the con- (door) operates in the proper direction troller in the run mode. when the up (▲) and down (▼) keys are If the controller is in any service level and there is no pressed. keypad activity for 30 minutes, the controller will auto- ● matically reset and return to the run mode. 3. After the reset ( ) key has been pressed one time, verify the motor rotation by briefly pushing the up INITIAL START-UP (▲) and down (▼) keys on the control panel. The door should open with the up (▲) key and close with the down (▼) key. If the door does not operate in this manner, reverse two of the motor wires (not the incoming three-phase supply wires). Initial system start-up is only to occur once the door and control panel have been NOTE: Reversing the incoming supply voltage properly installed, wired, and all prelimi- lines will not solve the problem if the motor nary door adjustments made. Failure to is running in the wrong direction. The follow the instructions as outlined in the motor leads T1 and T2 must be swapped installation manual that was provided with to change motor rotation. If the motor your door can result in damage to the door rotated incorrectly during the start-up pro- upon initial system start-up. cess, the limits may need to be reset by entering P:210 and setting a value of 5.

The RESET key also serves as the ENTER key and the STOP key.

When limits are established, the display 4. Now set the door open and close limits according to will prompt you to push the down key and the instructions on the display. begin the auto-calibration process. I:500 If any error messages are displayed, some of the messages will appear on the display. This required input connections may be missing. Once is normal. The I:500 messages should dis- the missing inputs are connected, perform the appear within 10 complete cycles. Keep open and close limit set-up. Otherwise, refer to hands and equipment away from the door “FAULT CODES” on page 35. until the auto-calibration is complete. NOTE: When establishing the open- and close- 1. Release the brake located on the end of the motor limit positions, refer to the installation and manually move the door to the half-open manual that came with your door. position. 2. Apply power to the control system. During the system initialization, the display will indicate that the door open and close limits must be set by displaying “! Set Limits !”. (See Figure 24.) Then the message “Push ●” [press reset (●) key] will appear on the display.

15 SYSTEM START-UP—ACCESSING PARAMETERS

Parameters

P:C06 = Adjusts the year of the clock When limits are established, the display will prompt you to push the down key and P:C07 = Adjusts for daylight saving time begin the auto-calibration process. I:500 messages will appear on the display. This NOTE: See “CLOCK PARAMETERS” on page 34 is normal. The I:500 messages should dis- for more information on the clock parame- appear within 10 complete cycles. Keep ters. hands and equipment away from the door until the auto-calibration is complete. ACCESSING PARAMETERS NOTE: To access Operator Level and Service 5. Once the limit-setting procedures have been com- Level 2 parameters, the control board ser- pleted, the door will automatically cycle until the vice switch must be in the ON position. auto-calibration is complete (typically 5–10 com- (See Figure 25.) plete cycles). This is done to optimize performance and will allow the door to run smoothly and effi- ciently. NOTE: The door will fine-tune the speed setting based on the programmed limits during the first several cycles. The informational Scrolling messages I:510, I:515, I:520, and I:555 Display will and may appear during the first 10 cycles of the door operation. This is normal, as the controller is optimizing the operational curve of the AC drive and motor. The door may run erratically during this process. DO NOT change any speed Service Switch or limit parameters during this time. If the message does not disappear from the display after 15 cycles, contact Rytec Techni- cal Support at 800-628-1909.

6. Set ACL1 and ACL2 timers as required. (See “SYS- TEM PARAMETERS” on page 26.) Terminal Block(s) Clock Setting Procedure Ter minal Screws The System 4 control panel has been shipped with the internal clock set with the date and central time. If your time zone is different, the clock can be adjusted. To adjust the clock, see “Navigating Parameters” on page 17. Table 1 A5400016 Figure 25 Parameters Parameter Messages P:C00 = Shows the current date and time the System A scrolling display on the control panel (as shown in 4 clock is set to Figure 26) displays all parameter settings when the control system is placed in a service level (Operator Level or P:C01 = Adjusts the hour of the clock Service Level 2). Figure 26 details a typical parameter. P:C02 = Adjusts the minutes of the clock

P:C03 = Adjusts the seconds of the clock

P:C04 = Adjusts the day and month of the clock

16 SYSTEM START-UP—ACCESSING PARAMETERS

• Simultaneously press and hold the up (▲) and reset (●) keys for approximately three seconds. The con- Three-Digit Parameter trol system will enter the Operator Level and display Parameter Operator Level (O) Name or Group Number Service Level 2 (S) the last-saved operator parameter. (To access the upper service level(s), see “Accessing Service Level 2” on page 18.) P: • Continually press the up (▲) or down (▼) key to = scroll through the list of available parameters. Hold- ing either key speed-scrolls you through the list. Parameter • Press the reset (●) key to access the displayed Value Unit Read/Write (=) Parameter parameter. The parameter is accessed when the Read Only (#) Status cursor jumps over to the currently saved value for that parameter. (See Figure 29.) ▲ ▼ Figure 26 • Continually press the up ( ) or down ( ) key to scroll through the list of available parameter values. For example, Figure 27 details door limit set-up param- Holding either key speed-scrolls you through the eter 210 (P.210). list. • Pressing the enter (●) key saves the displayed Three-Digit Parameter value. Press and hold the enter key until a check- Parameter Name or Group Operator Level (O) Number Service Level 2 (S) mark appears to the right of the value you wish to enter. (Note: If the enter (●) key is not held down long enough, the display will return to the previously P:Posi t ioni ng S saved setting.) A checkmark next to the displayed 210– = 09 # value indicates the currently saved value. An aster- isk next to the displayed value indicates a value that Cursor is not saved. (See Figure 30.) Parameter Unit Parameter • Pressing and releasing the enter (●) key jumps the Value Status cursor back over to the three-digit parameter num- Figure 27 ber. Figure 28 details password parameter 999 (P.999). NOTE: The RESET key also serves as the ENTER key and the STOP key. Three-Digit Parameter See Table 5 on page 26 for a complete list of Parameter Operator Level (O) Name or Group parameters available through the Operator Level. Number Service Level 2 (S)

P:Password P:Posi t ioni ng S 999= 0 01 09 # – 210– = 09 #

Cursor Parameter Parameter Unit Cursor Position Cursor Position Value Parameter Status Number when Scrolling Once Parameter through Parameters Is Accessed Figure 28 Figure 29 Navigating Parameters The following procedure explains how to navigate through the parameters. The procedure is the same regardless of the service level. 1. To navigate the parameters:

17 SYSTEM START-UP—ACCESSING PARAMETERS

4. Press the enter (●) key to accept the password and Three-Digit Parameter enter that particular service level. A checkmark will Parameter Name or Group Operator Level (O) Number Service Level 2 (S) appear to the right of the value entered. Release the enter (●) key, then press and release the enter (●) key once more. The cursor will jump back under the P:Posi t ioni ng S three-digit parameter number and a large “S” will 210– = 59 # appear on the display to indicate that Service Level 2 is accessed. Cursor NOTE: The RESET key also serves as the Parameter Unit Parameter Value ENTER key and the STOP key. Status 5. Press the up (▲) or down (▼) key to scroll through Figure 30 the list of available parameters for that particular Accessing Service Level 2 service level. (Only the parameters associated with 25 the accessed service level, will be available.) 1. Access the Operator Level. (See “Navigating Parameters” on page 17.) 6. Access a displayed parameter by briefly pressing the enter (●) key. The parameter is accessed when 2. To access Service Level 2, scroll to password the cursor jumps over to the currently saved value parameter 999 (P.999). Then briefly press and for that parameter. release the reset (●) key. The cursor will jump from the three-digit parameter number over to the param- Setting Door Limits (Open, Intermediate, and Close) eter value on the display. (See Figure 31.) 1. Access parameter P.210. (See “Navigating Param- eters” on page 17.) Three-Digit Parameter ▲ ▼ Parameter Operator Level (O) 2. Press the up ( ) or down ( ) key until the desired Name or Group Number Service Level 2 (S) door limit option is displayed. Pressing and holding the enter (●) key will save the displayed option. NOTE: The RESET key also serves as the P:Password O ENTER key and the STOP key. 999– = 0 00–0 9 # 3. Follow the instructions on the display to set the door limits. Cursor Parameter Unit Parameter Setting Automatic Delay Timers Value Status 1. Access the Operator Level. (See “Navigating Figure 31 Parameters” on page 17.) 3. Enter the password by first pressing the up (▲) or 2. Press the up (▲) or down (▼) key until the desired down (▼) key until the numerical password required delay timer parameter is displayed (P.010 = ACL1, for the desired service level is displayed. P.011 = ACL3, P.015 = ACL2). (See Figure 32.) Figure 33 shows that auto-close delay timer ACL1 is currently set with an eight (8) second delay. Three-Digit Parameter Parameter Operator Level (O) Name or Group Three-Digit Number Service Level 2 (S) Parameter Parameter Operator Level (O) Name or Group Number Service Level 2 (S) P:Password S 999= 1 0 # 9 P:Ac l 1 O 0 10= 89 # Parameter Value – (Numerical Password Unit Service Level 2) Parameter Cursor Status Parameter Unit Value Parameter Figure 32 Status

Figure 33

18 SYSTEM START-UP—SYSTEM RESET (MANUAL RESET)

3. With the desired timer parameter displayed, press the enter (●) key to access that parameter. The cur- NOTE: Clear plastic cover is shown for sample purposes. sor will jump over to the parameter value. NOTE: The allowable time delay range for a timer is 0 to 9999 seconds.

The RESET key also serves as the ENTER key and the STOP key.

4. Press the up (▲) or down (▼) key to change the displayed value. Press and hold the enter (●) key to save the displayed value. Mobile Unit SYSTEM RESET (MANUAL RESET) A system reset is necessary after the control system displays an error message and the problem resulting in A2500246 that error message has been corrected. To reset the Figure 34 control system, press and hold the reset (●) key for approximately three to five seconds. If the display clears and the message reappears, the problem has not been corrected and will need further investigation. NOTE: The RESET key also serves as the ENTER key and the STOP key.

Once the reset is complete, if the door was is the full- open or -closed position prior to the error message, the Antenna display will indicate the door type and cycle count. If the Prongs door was in a position other than the full-open or -closed position, the display will indicate the door is stopped. After the system is reset, the door can be normally operated with the up (▲), down (▼), and reset (●) keys.

DEFROST SYSTEM A2500247

If your door is configured with an optional defrost sys- Figure 35 tem, the System 4 Drive & Control is designed to operate and monitor that system. Attached to the electric motor is a small tan-colored cable. The tan cable is routed from inside the motor See “SYSTEM PARAMETERS” on page 26 for addi- assembly, through the front head assembly, and to the tional information on setting the defrost system controls. mounting bracket of the front spreader. When the WIRELESS REVERSING EDGE bracket is installed, the 2-inch prongs from the antenna will point toward the drum roll and the tan cable should The wireless system has two main assemblies: the exit the bottom of the antenna. mobile unit located in the bottom bar under the plastic (See Figure 36 and Figure 37.) cover and the stationary antenna located in the head assembly. (See Figure 34 and Figure 35.) All mobile NOTE: No bends, kinks, or loops are allowed in units are installed at Rytec prior to shipping. The wire- the tan cable. The antenna is fragile and less antenna may or may not be installed by Rytec prior should be handled with extreme care. to shipping. Some Rytec models require the antenna to be installed in the field. Please reference the specific Any leftover packaging material should be product installation manual for your model of Rytec removed from the antenna prior to installa- door. The antenna has a tan-colored cable that runs to tion. the encoder, which is mounted to the back of the motor, and a black cable from the encoder that carries the signals for the reversing edge and the breakaway back to the System 4 control board.

19 SYSTEM START-UP—WIRELESS REVERSING EDGE

Parameters for Wireless System The control system for the wireless reversing edge has been programmed at Rytec. However, field adjustments may be required. Below is a list of the applicable param- Antenna Prongs Point Toward the Drum Roll eters and fault codes associated with the wireless reversing edge system. NOTE: Do not make any changes to the wireless system until you have contacted Rytec Technical Support at 800-628-1909. Access for programming parameters can be found in the Rytec System 4 Drive & Control manual that is shipped with the door in the small parts carton.

Tan Cable

A7700019 Figure 36

Antenna Prongs Point Toward the Drum Roll

Drum Roll

Line of Sight

Mobile Unit

A2500249 Figure 37

20 SYSTEM START-UP—WIRELESS REVERSING EDGE

Table 2 Parameters

Parameters P:F09 = Battery low 3.6 volts

P:F00 = Activates the wireless system When battery voltage drops below the preset value, an error will be displayed = F 857 Battery low. 1 = On, 0 = Off If voltage falls below the preset level, F:857 will be P:F01 = Packet timeout before “edge trip” occurs displayed on the screen. The door will remain opera- Adjustment made in milliseconds = 6 ms to 250 ms tional with the message displayed, but the battery will need to be changed soon. If the battery goes com- NOTE: 50 ms is default. pletely dead, F:856 will appear and the door will not function. The battery is a 3.8 Lithium and about the P:F05 = Channel group same size as a standard “D” size battery. Part 1–10 Factory setting (can only be viewed in parame- number 00111193. ter mode) NOTE: Figure 39 shows the battery through a P:F07 = Mobile unit address clear cover located in the bottom bar. Clear cover shown is a sample piece. • Unique to each unit NOTE: Battery for wireless reversing edge: • Hexadecimal number located on the transmitter brown wire (+), blue wire (–). unit in the bottom bar (See Figure 38.)

NOTE: Hexadecimal address should be the same value as Parameter P:F07.

Mobile Unit Address

A2500246

Figure 39

A2500250 Table 3

Figure 38 Error Codes IMPORTANT: The hexadecimal number on the transmitter unit must be F 856 = No communication between the stationary facing to the left when installed and mobile units for more than ten seconds in the bottom bar. When facing • Antenna not connected or poorly mounted the front of the door, the Rytec decal will be seen to the right • Battery is dead

of the mobile unit. • Mobile unit address is incorrect

After entering the address, it • No mobile unit found

is necessary to check that the • Strong electrical interference in the frequency controller is connected and range working with the selected mobile unit. Since the number F 857 = Battery monitoring

system is hexadecimal, it is • Battery voltage falls below value in P:F08 possible to have letters included in the mobile unit • New battery is required address. For example: 1C46, 89D3, and 65B1.

21 SYSTEM START-UP—WIRELESS REVERSING EDGE

Table 4

Encoder Cable Connections System 4 Control Panel NOTE: The encoder cable is to be cut to length. DO NOT leave excessive cable inside the control panel.

NOTE: Connections below are for the wireless reversing edge connections only. Refer- ence the electrical schematic that was shipped in the control panel for specific connections for your particular door. Encoder connections may vary depending on door models.

Encoder Cable: System 4 Control Board:

Brown (+24 VDC) to terminal #270

Red (Ajar) to terminal #271

Pink (Reversing Edge) to terminal #272

Gray to terminal #273

Blue to terminal #274

Yellow (RS485 a) to terminal #275

Green (RS485 b) to terminal #276

White (Ground) to terminal #277

The encoder cable is vital for proper door operation. Trim the cable end to expose the drain wire (bare sil- ver) but do it such a manner as not to damage the drain wire and most importantly the shield. NOTE: Shield and drain wire should be cap- tured under the P-clip below terminals 270–277. (See Figure 40.)

DO NOT ground to control board or motor ground.

22 SYSTEM START-UP—WIRELESS REVERSING EDGE

A5400031 Figure 40

23 SYSTEM START-UP—WIRELESS REVERSING EDGE

Reversing Edge Jumper

A5400014 Figure 41 NOTE: The configuration of the jumpers should have been done at Rytec prior to shipping. This information is provided just to confirm the accurate setting of the jumpers. (See Figure 41.)

24 SYSTEM START-UP—WIRELESS REVERSING EDGE

Jumpers on the System 4 Control Panel

1.2K ohm Jumper

8.2K ohm Jumper

A5400014 Figure 42 NOTE: Jumper for the reversing edge should be configured for 8.2K ohms. (See Figure 42.)

Please contact Rytec Technical Support at 800-628-1909 if there are any questions or concerns.

25 SYSTEM PARAMETERS—OPERATOR LEVEL PARAMETERS

SYSTEM PARAMETERS The system parameters are grouped into two levels: OPERATOR LEVEL PARAMETERS "OPERATOR LEVEL PARAMETERS" and “SERVICE Table 5 below lists the parameters available through the LEVEL 2 PARAMETERS” on page 27. Operator Level. Included in this table is a description of each parameter and its available range and factory default setting. Table 5

Factory Parameter Range Operator Level Parameters (Password Not Required) Setting

P.010 0–200 seconds Auto-close delay timer 1 — ACL1 (with activator connected to 10 input 5 — terminals 210 and 212) 0 = Off Time door remains open after all activation and safeties are clear

P.011 0–200 seconds Auto-close delay timer 3 — ACL3 (0 = off) 0 The ACL3 timer is available for all doors. The input selected will need to be programmed to operate through the ACL3 timer.

P.015 0–200 seconds Auto-close delay timer 2 — ACL2 (with activator connected to 5 input 6 — terminals 230 and 233) 0 = Off Time door remains open after all activation and safeties are clear

P.050 (Defrost 0–3 Heater status 0 System Only) 0: Off 1: On — low heat stage 1 heated blower or heat lamps 2: On — medium heat stage 1 + 2 heated blower 3: On — high heat stage 1 + 2 + 3 heated blower

P.051 (Defrost 0–1 Heater control (parameter P.050 must be set to on) 0 System Only) 0: Manual 1: Automatic timer

P.055 (Defrost 0–3 Blower control 0 System Only) 0: Off 1: Low speed 2: High speed 3: Automatic (blower runs at high speed when door is open)

P.058 (Defrost 5–600 minutes Heater timer on time 30 System Only)

P.059 (Defrost 5–600 minutes Heater timer off time 5 System Only) P.999 Password (for accessing Service Level 2) is the number 10. Password (for accessing Service Level 1) is the number 5.

26 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

SERVICE LEVEL 2 PARAMETERS At Service Level 2, the technician will be able to view all the parameters in the System 4 Control panel. However, Table 6 below lists some of the parameters available some parameters (Safety) will require an additional through Service Level 2. Included in this table is a Rytec level password to do the changes. description of each parameter and its available ranges and factory default settings. Table 6

Factory Parameter Range Service Level 2 Parameters Setting

P.000 Cycles Door cycle counter (read only)

P.001 Cycles Saved door cycle counter NOTE: This is used to lock in the current door cycle count for entering Rytec service level passwords. Rytec level passwords are only available through the Rytec Technical Support Department at 800-628- 1909.

P.005 Cycles Maintenance counter NOTE: This indicates the number of cycles remaining until door maintenance is due. This parameter works in conjunction with P.970 & P.971. The factory setting is –1, meaning not turned on. P.005 counts down one cycle from the value in P.971 each time the door operates. For example, if P.971 is set to 100 cycles, each time the door opens P.005 counts down from 100, 99, 98 etc., until it reaches 0. P.970 instructs the door what to do when the counter reaches 0. See P.970 for selec- tions.

P.010 0–9999 seconds Auto-close delay timer 1 — ACL1 (with activator connected to 10 input 5 — terminals 210 and 212) 0 = Off

P.011 0–9999 seconds Auto-close delay timer 3 — ACL2 (with activator connected to 10 input 6 — terminals 230 and 233) 0 = Off

P.015 0–200 seconds Auto-close delay timer 2 — ACL2 (with activator connected to 5 input 6 — terminals 230 and 233) 0 = Off Time door remains open after all activation and safeties are clear

P.017 0–999 seconds Storage of open commands 0 NOTE: Open commands can be stored with this parameter. If the door is interlocked and when the interlock is released, this timer counts down and opens the door. To turn off the storage of OPEN commands, change value of P:017 to 0.

27 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory Parameter Range Service Level 2 Parameters Setting

P.025 0–20 seconds Pre-warning time before close 3 NOTE: This parameter is used for the yellow flashing warning lights. Increasing the value will increase the number of times the yellow LEDs flash previ- ous to closing.

P.026 0–1 Pre-warning time before opening 0

P.051 (Defrost 0–1 Heater control (parameter P.050 must be on) 0 System Only) 0: Manual 1: Automatic timer. Timer settings found in parameters P:058 (time heater is ON) and P:059 (time heater is OFF).

P.055 (Defrost 0–3 Blower control 0 System Only) 0: Off 1: Low speed 2: High speed 3: Automatic (blower runs at high speed when door is open)

P.058 (Defrost 5–600 minutes Heater timer on time 30 System Only)

P.059 (Defrost 5–600 minutes Heater timer off time 5 System Only) P.210 0–5 Limit set-up 0 0: Off 1: Open, close, and partial set-up (partial set using P.244) 2: Open 3: Open and close 4: Partial (P.244 ignored) 5: All (partial set using P.244)

P.221 ± 125 increments Close-limit adjustment 0 (For minor adjustments to the close position of the door. This adjustment resets to 0 if the limits are reset. Ten increments equals approximately 1 inch of door travel.)

P.231 ± 60 increments Open-limit adjustment 0 (For minor adjustments to the open position of the door. This adjustment resets to 0 if the limits are reset. Ten increments equals approximately 1 inch of door travel.)

P.244 0–3 Partial position 0 0: Parameter off 1: Half-open position 2: Two-thirds-open position 3: Operator-established position

28 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory Parameter Range Service Level 2 Parameters Setting

P.630 0–2 Function keypad OPEN 2 (Specifies the function (mode) of the OPEN key) 0: No door function 1: Only deadman move during deadman operation 2: Deadman and automatic NOTE: This parameter is used for security purposes. For example, if the owner wants to monitor who is accessing the door via a card swipe, then the UP arrow on the control panel must be deactivated. Otherwise, simply pushing the UP arrow will allow anyone into the room. Changing parameter P:630 to 0 forces entry via the card swipe. The arrow will remain functional for navigating the parameters but will not operate the door. The same condition applies to parameter P:650 for the close key.

P.640 0–2 Function keypad STOP 0 (Specifies the function (mode) of the STOP key) 0: No door function during automatic travel 1: After pressing the STOP key, the door is stopped and waits for any command 2: After pressing the STOP key, the door is stopped and waits for a keypad command NOTE: The RESET key also serves as the ENTER key and the STOP key.

P.650 0–2 Function keypad CLOSE 2 (Specifies the function (mode) of the CLOSE key) 0: No door function 1: Only deadman move during deadman operation 2: Deadman and automatic

P.660 0–4 Floor loop detector — channel 1 function 1 20: Deactivated 21: Command forwarding 22: Open command (Additional settings are also available under this parameter.) Locking, safety, sequence of operation are all available if needed. Contact Rytec Technical Support at 800-628-1909 to discuss specific operational sequence.

P.670 0–4 Floor loop detector — channel 2 function 1 20: Deactivated 21: Command forwarding 22: Open command (Additional settings are also available under this parameter.) Locking, safety, sequence of operation are all available if needed. Contact Rytec Technical Support at 800-628-1909 to discuss specific operational sequence.

29 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory Parameter Range Service Level 2 Parameters Setting

P.683 0–3 Open position — radio channel 1 0 0: Full-open position 1: Partial-open position 2: Partial-open when radio is activated one time, full-open when activated a second time 3: Full-open when radio is activated twice

P.693 0–3 Open position — radio channel 2 0 0: Full-open position 1: Partial-open position 2: Partial-open when radio is activated one time, full-open when activated a second time 3: Full-open when radio is activated twice

Table 7

Factory Parameter Range Service Level 2 Parameters Setting

NOTE: All inputs have the ability to be configured in many different ways. If you are interested in configuring an input, please contact Rytec Technical Support at 800-628-1909. Please have details available on what sensor you would like to use and how you would like the sensor to perform.

Contact Rytec Technical Support at 800-628-1909 for specific information regarding input configuration. The Rytec Technical Support group has performed many different input configurations and can help you determine which configuration is best suited for your environment. Please provide door serial number when contacting Rytec Technical Support.

P.7x0 The System 4 Drive & Control Ry-Wi System provides two out- NOTE: The “x” in put relays and an expansion board that provides another six P.7x0 represents the relay number. that can be configured a number of different ways. Example P:710 represents relay number 1 and P:720 represents If you are interested in configuring an output relay to perform a relay number 2 and so specific function, please call Rytec Technical Support at 800- forth. Up to eight possible relays can be used. 628-1909. Please be sure to have all operational details prior to contacting Rytec.

Any and all options are available for the outputs to perform a variety of operations. The relays can be programmed to perform many different scenarios.

30 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Table 8

Factory Parameter Range Service Level 2 Parameters Setting

P.910 0–25 Display mode selection The following variables are displayed: 0: Control sequence is displayed, i.e., door cycles, door opening, timer, door closing. 1: [Hz] The current travel speed 2: [A] The current motor current 3: [V] The current motor voltage 4: [A] The current DC bus current 5: [V] The current DC bus voltage 6: [°C] The power stage temperature in °Celsius 7: [°F] The power stage temperature in °Fahrenheit 8: [s] The run time of the motor during the last door operation 9: [Increments] The current position 10: [Increments] The position of the reference 11: [Dig] Channel 1 value of the absolute encoder 12: [Dig] Channel 2 value of the absolute encoder 13: [V] Current reference voltage 14: Temperature inside the controller in celsius degrees 15: Temperature inside the controller in fahrenheit degrees 16: Transmission ratio from motor to encoder during opening 17: Transmission ratio from motor to encoder during closing 18: Rotation speed of the motor output shaft 19: Temperature of the encoder 20: Battery voltage of encoder 21: Number of position requisition without answer 22: Number of position requests from the board to the encoder without an answer from the encoder 23: Wireless reversing edge signal strength during door travel. Given in a percentage of signal. Percentage should remain above 90% during travel. 24: Numbers of wireless reversing edge errors during the last door cycle 25: Time of the clock in the controller. NOTE: Settings 14 and 15 are only available if optional temperature sensor is installed in the controller.

P.920 Error history (The controller stores the last eight errors in the error history. The System 4 controller will time stamp the errors with the date and time the error occurred.) Error message 1 (most recent error) Error message 2 Error message 3 Error message 4 Error message 5 Error message 6 Error message 7 Error message 8 Clear the complete error history Exit the error memory, jump back to parameter

31 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory Parameter Range Service Level 2 Parameters Setting

P.940 Volt Input voltage (The real-time voltage the board is receiving. Electrical meters measure the voltage as an RMS or essentially an average; therefore, an electrical meter reading may vary by 20 volts or more. P:940 displays the voltage in real time. If the control board receives a voltage greater than 10%, its rating error F:525 will appear until the voltage drops back down within acceptable range. If this continues, a line reactor will be needed to prevent the failure. When incoming power is ungrounded, an isolation transformer may be needed. (Part number for the line reactor is 0011748 and the isolation transformer is part number 00111101.)

P.980 0–5 Operating mode 0 (This parameter is used to set the operating mode for the controller) The following modes are possible: 0: Door travels in automatic mode. 1: Door opens in automatic, closes in manual (jog) mode. 2: Door travels in jog mode open and close. 3: Jog mode only (deadman) emergency operation; and no safety inputs required for deadman operation.

All safety devices and limit switches are ignored.

4: Endurance test with safety devices automatic OPEN and CLOSE operation. Before each new operation the hold-open time P.010 is in effect. 5: Endurance test without safety devices.

All safety devices are ignored.

NOTE: The endurance test setting is lost after turning off the controller. The controller then reverts to manual mode. This will require parameter P:980 to be set to 0 before automatic operation can be preformed.

P.985 0–3 Text language 0 0: English text 1: German text 2: Spanish text 3: French text

P.999 Password (for accessing Service Levels 2) is the number 10.

P.F00 0–1 Activation of the wireless (Activate the functions of the wireless in the controller)

32 SYSTEM PARAMETERS—SERVICE LEVEL 2 PARAMETERS

Factory Parameter Range Service Level 2 Parameters Setting

P.F01 6–250 Timeout for the wireless 50 milliseconds (This sets the wireless timeout within the controller) NOTE: If the mobile unit doesn’t send a message within the specified time, the wireless edge will be seen as tripped.

P.F05 1–10 Channel group 1 (The channel group of the wireless connection) Channel is selectable 1–10. Find setting with highest percentage during door operation. Use P:910 set to 23 to display percentage during door travel. Place P:910 back to 0 when finished testing wireless signal.

P.F07 00000000– Mobile unit address FFFFFFFF (The address on the mobile unit is used to communicate with the encoder via the antenna in the head assembly. Each mobile unit has its own address number.)

Mobile Unit Installed in Bottom Bar Address

A2500246

Figure 43

NOTE: The mobile address is shown mounted on the mobile unit.

Mobile Address A5500025 Figure 44

33 SYSTEM PARAMETERS—CLOCK PARAMETERS

Factory Parameter Range Service Level 2 Parameters Setting

P.F08 0–3.5 Volts Battery voltage warning level (The warning level for the battery voltage. If the battery voltage is less than the specified value, an F857 will occur.)

CLOCK PARAMETERS password of “10” to enable you to change the clock setting. Table 9 details the parameters used to adjust the If the clock time needs to be changed to your time zone, clock setting. Service Level 2 will be required. P:999 will require a Table 9

Parameter Range Service Level 2 Parameter

P:C00 Displays the current time and date of the System 4 clock. Clock is set at Rytec before shipping to current date and central time.

P:C01 0–23 hours Adjusts hours for the current time.

P:C02 0–59 minutes Adjusts minutes for the current time.

P:C03 0–59 seconds Adjusts seconds for the current time

P:C04 0101–1231 Adjusts day and month to current day and month.

P:C06 2000–2099 Adjusts year to current year.

34 SYSTEM PARAMETERS—FAULT CODES

FAULT CODES Table 10 lists the fault codes associated with the general operation of the door. Included in this table are the avail- GENERAL OPERATION FAULT CODES able fault codes, a description of each fault code, and NOTE: If you have an error not listed in the chart the suggested corrective action to clear the fault. (Door below, contact Rytec Technical Support at is in the error jog only mode.) 800-628-1909. Table 10

Fault Code Description Corrective Action (Displayed Message)

F.000 Door opens past full-open position. 1. Repair or adjust motor brake. (Beyond Opn) 1. Motor brake faulty or improperly adjusted 2. Consult factory with door serial number. (beyond open) 2. Door position parameters incorrect

F.005 Door closes past full-closed position. 1. Repair or adjust motor brake. (Beyond Clsd) 1. Motor brake faulty or improperly adjusted 2. Consult factory with door serial number. (beyond closed) 2. Door position parameters incorrect

F.020 Door open run time exceeded. 1. Check mechanical operation of door. (Beyond Runt) 1. Blocked door 2. Check motor. Verify that the motor is (beyond run time) 2. Sluggish motor wired to proper voltage. Reference door 3. Run time set too low electrical schematic for correct motor voltage — high or low. 3. Consult factory with door serial number.

F:021 The maximum allowed run time for emer- 1. Check incoming power L1, L2, L3. (Emergency Opening gency opening has been exceeded. 2. Check motor. Verify that the motor is Wrong Testing) wired to proper voltage. Reference door electrical schematic for correct motor voltage — high or low. 3. Check for mechanical bind. 4. Verify motor brake is releasing. 5. Consult factory with door serial number.

F.030 Door travel incomplete (check incoming 1. Check mechanical operation of door. (Mtr Stalled) power at L1, L2, and L3 on the control 2. Check motor and brake. (motor stalled) board). 3. Check encoder mounting. 1. Blocked door 4. Check encoder operation. 2. Jammed motor 5. Consult factory with door serial number. 3. Encoder incorrectly installed NOTE: Check that cables are cut to 4. Encoder problem length and that high- and 5. Low start torque or speed low-voltage lines are in separate conduits.

F.031 Door moves in wrong direction. 1. Check encoder and encoder connec- (Trv Direct) 1. Encoder wired incorrectly tions. (travel direction) 2. Motor running in wrong direction 2. Check motor rotation. If motor rotation is 3. Motor brake releases early incorrect, swap the T1 and T2. The limits will need to be cleared in parameter 210. NOTE: The controller knows the motor was rotating back- wards. You will receive an encoder fault if limits are not cleared and reset.

3. Consult factory with door serial number.

35 SYSTEM PARAMETERS—GENERAL OPERATION FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:033 No door travel or inconsistent travel. 1. Check encoder mounting. (Bad position trans- 2. Check encoder connections. mitter protocol) 3. Verify encoder counting, P:910 set to 9 to watch count. 4. Check incoming power. 5. Consult factory with door serial number.

F:035 Door does not close properly. 1. Check encoder mounting and encoder (Lag error during hub attached. Make sure all are tight. closing) 2. Check motor. Verify that the motor is wired to proper voltage. Reference door electrical schematic for correct motor voltage — high or low. 3. Check motor brake is functional. 4. Check for mechanical bind. 5. Consult factory with door serial number.

F:036 Door not operating properly. 1. Consult factory with door serial number. (Date crash detected)

F:040 Door moves without being activated or 1. Check for brake voltage. (Defective brake) moves unexpectedly. 2. Check mechanical aspects of motor brake. 3. Adjust brake gap.

F:043 The pre-limit switch for the light barrier 1. Check the value of parameter P:222 (Pre-limit switch fault, remains active in middle or open position. pre-limit close. photo eyes, or light The pre-limit turns the light barrier off and 2. Consult factory with door serial number. curtain.) on in certain positions of the door travel. This fault is indicating the pre-limit is not functional.

F:050 Open or close limit position always active. 1. Set parameter P:910 to 9 and watch (Encoder position Limits activated in different positions encoder count during opening and close. deviates from permis- throughout the door travel. 2. Check encoder mounting. sible range during 3. Consult factory with door serial number. synchronization.)

F:051 Encoder increment count is beyond the limit 1. Set parameter P:910 to 9 and watch (Encoder position band. encoder count during opening and close. deviates from permis- 2. Check encoder mounting. sible range.) 3. Consult factory with door serial number.

F:052 Controller does not recognize the limit posi- 1. Set parameter P:910 to 9 and watch (Limit position not tion the encoder is sending. encoder count during opening and close. recognized.) 2. Check encoder mounting. 3. Consult factory with door serial number.

36 SYSTEM PARAMETERS—GENERAL OPERATION FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F.060 Bottom bar breakaway input activated, ter- Reassemble bottom bar or repair break- (Door Ajar) minal 271. away switch. The controller believes the door was impacted and the panel is outside the side columns. Reassemble bottom bar or repair breakway switch. NOTE: If an error reappears after resetting the error, it has not been corrected. If the door has a coil cord, a wire for the breakaway circuit may be broken inside the coil cord.

F:063 Controller receiving signal from loop 3; 1. Remove any sources of EMI in area. (Balance Error Loop 3) however, something is disturbing the signal. 2. Test ground loop 3 with megohm meter for continuity and continuity to ground. 3. Consult factory with door serial number.

F:064 Controller receiving signal from loop 4; 1. Remove any sources of EMI in area. (Error Loop 4) however, something is disturbing the signal. 2. Test ground loop 4 with megohm meter for continuity and continuity to ground. 3. Consult factory with door serial number.

F:067 Loop 3 has either a broken wire or a short 1. Test continuity of loop 3 with megohm (Error Loop 3) circuit between the loop wires. meter. 2. Test continuity of loop 3 to ground with megohm meter. 3. Replace loop 3. 4. Consult factory with door serial number.

F:068 Loop 4 has either a broken wire or a short 1. Test continuity of loop 4 with megohm (Error Loop 4) circuit between the loop wires. meter. 2. Test continuity of loop 4 to ground with megohm meter. 3. Replace loop 4. 4. Consult factory with door serial number.

F.070 Clean position reached. Door is in the “Clean” position. (Clean Pos) 1. Push UP arrow once to position door (clean position) into the close position. 2. Push UP arrow a second time to operate the door.

F:080 Maintenance counter has expired. 1. Perform required maintenance or (Maintenance planned maintenance. Required) 2. Set P:973 to 1 to reset maintenance counter.

F:090 The controller does not have the necessary 1. Consult factory with door serial number. (Controller not minimal parameters set to operate. parameterized)

37 SYSTEM PARAMETERS—DOOR SAFETY/EMERGENCY FAULT CODES

DOOR SAFETY/EMERGENCY FAULT CODES Table 11 lists the fault codes associated with the door safety/emergency system. Included in this table are the available fault codes, a description of each fault, and the suggested corrective action to clear the fault. (The door is in the emergency stop mode and will not operate.) Table 11

Fault Code Description Corrective Action (Displayed Message)

F.201 1. Door stopped and does not operate 1. Reset E-Stop 1. (E-Stop 1) 2. Corresponding error message displayed 2. Check jumper terminals 240 and 241 NOTE: Terminals can be used for emergency stop push button in place of the jumper. Switch must be normally closed.

F.211 External Emergency Stop activated. 1. Reset E-Stop 2. (E-Stop 2) 1. Door stopped and does not operate 2. Check jumper terminals 250 and 251 2. Corresponding error message displayed NOTE: Terminals can be used for emergency stop push button in place of the jumper. Switch must be normally closed.

F.212 External Emergency Stop activated. 1. Reset E-Stop 3. (E-Stop 3) 1. Door stopped and does not operate 2. Check jumper terminals 260 and 261 2. Corresponding error message displayed NOTE: Terminals can be used for emergency stop push button in place of the jumper. Switch must be normally closed.

F:320 Door encountered an obstruction on opening. Consult factory with door serial number. (Obstacle during Error should not appear as this function is not open) utilized at this time.

F:325 Door encountered an obstruction on Closing. Consult factory with door serial number. (Obstacle during Error should not appear as this function is not close) utilized at this time.

38 SYSTEM PARAMETERS—REVERSING EDGE CIRCUIT FAULT CODES

REVERSING EDGE CIRCUIT FAULT CODES Table 12 below lists the fault codes associated with the reversing edge circuit. Included in this table are the available fault codes, a description of each fault code, and the suggested corrective action to clear the fault. (The door is in the error jog only mode.) Table 12

Fault Code Description Corrective Action (Displayed Message)

F:360 Controller has detected a short in the 1. Check reversing edge switch for open (Short circuit reversing edge system. Wireless system contact. detected on edge utilizes normally open contact in conjunc- 2. Ohm resistor, 8.2K ohms. input.) tion with 8.2K ohm resistor. Controller mea- 3. Remove reversing edge wires from suring 0 ohms at edge input. mobile unit (black and red wires) and measure for 8.2K ohms. 4. Verify jumper in correct position on control board. (See Figure 42 on page 25.) 5. Consult factory with door serial number.

F.361 Reversing edge tripped. 1. Reset control system. (Edge Trip) 1. Bottom edge of door made contact with 2. Check and repair wiring. (edge trip) object in door opening 3. Check and adjust switch. 2. Short circuit in reversing edge wiring NOTE: Ohm reading on terminals 3. Pressure switch faulty or not adjusted 272 and 283 should read 8.2K or 8200 ohms.

All wireless units use a 8.2K ohm resistor.

F:362 The controller has a two-step process for 1. Check reversing edge switch for open (Redundancy error testing a short circuit in the edge; during this contact. with short circuit.) process the results were different. The 2. Ohm resistor, 8.2K ohms. results should be the same. This error typi- 3. Remove reversing edge wires from cally displayed with other edge errors, F:361. mobile unit (black and red wires) and measure for 8.2K ohms. 4. Verify jumper in correct position on control board. (See Figure 42 on page 25.) 5. Consult factory with door serial number.

F.363 Reversing edge circuit open. Check all parts of reversing edge circuit (Edge Open) 1. Reversing edge wiring disconnected including resistor. Make any necessary 2. Reversing edge cable in the bottom bar repairs or adjustments. Verify proper may be cut or damaged operation of reversing edge after all 3. Reversing edge resistor is wrong value repairs and adjustments are made. Ohm or missing reading is ohms at terminals. NOTE: All resistors are 8.2K ohms. Terminals 272 and 273.

39 SYSTEM PARAMETERS—REVERSING EDGE CIRCUIT FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:364 The controller tests the presence of the 1. Check reversing edge switch for open (Safety edge test reversing edge after each open cycle to contact. failed.) ensure edge is present before closing. If 2. Ohm resistor, 8.2K ohms. the edge does not respond during this test, 3. Remove reversing edge wires from F:364 is displayed. mobile unit (black and red wires) and measure for 8.2K ohms. 4. Verify jumper in correct position on control board. (See Figure 42 on page 25.) 5. Consult factory with door serial number.

F:365 The controller has a two-step process for 1. Check reversing edge switch for open (Redundancy error testing an open circuit in the edge; during this contact. with interruption.) process the results were different. The 2. Ohm resistor, 8.2K ohms. results should be the same. This error typi- 3. Remove reversing edge wires from cally displayed with other edge errors, F:363. mobile unit (black and red wires) and measure for 8.2K ohms. 4. Verify jumper in correct position on control board. See Figure 42 on page 29 for reference. 5. Consult factory with door serial number.

F:366 Defective optical safety edge. Rytec does Consult factory with door serial number. (Pulse frequency too not utilize optical safety edges. high for optical edge.)

F:369 The control recognizes an edge connected 1. P:460 needs to be set to 1. (Internal safety edge to the controller; however, the controller 2. Parameter change can only be accom- incorrectly parame- edge circuit needs to be turned on. plished with a Rytec level password. Must terized.) contact Rytec Technical Support at 800-628-1909 with door serial number for password.

40 SYSTEM PARAMETERS—DRIVE SYSTEM FAULT CODES (400-LEVEL CODES)

DRIVE SYSTEM FAULT CODES (400-LEVEL CODES) Table 13 lists the fault codes associated with the drive system. Included in this table are the available fault codes, a description of each fault code, and the suggested corrective action to clear the fault. Table 13

Fault Code Description Corrective Action (Displayed Message)

F.410 Over current. 1. Check operation of door. (Mtr OC L1) 1. Mechanical problem 2. Check brake. (motor over current 2. Motor brake not releasing 3. Check motor parameter settings and limit 1) 3. Motor nameplate parameters (frequency, verify settings match listing on motor current, etc.) incorrectly set nameplate. 4. Motor torque boost incorrectly set 4. Consult factory with door serial number. NOTE: Parameter P:140 (open boost) or P:145 (close boost) set too high.

F:413 Brake resistor under heavy load. Door trips 1. Confirm incoming power L1, L2, L3. (Brake chopper under fault to cool down brake resistor. After the 2. Ohm brake resistor, remove wires at heavy load) brake resistor cools down, the door will terminals X200 and X201 from main reset. board, reading should be 50 ohms. 3. Consult factory with door serial number.

F:420 Brake resistor is receiving too much voltage 1. Confirm incoming power L1, L2, L3. (Over voltage DC from motor, resistor is defective, door slow- 2. Ohm brake resistor, remove wires at Bus) ing down too fast. terminals X200 and X201 from main board, reading should be 50 ohms. 3. Consult factory with door serial number.

F.425 High supply voltage. Check parameter P:940 = (Power OV) 1. Incoming voltage too high incoming voltage to control board. (power over voltage)

F.426 Low supply voltage. Check parameter P:940 = (Power Low) 1. Incoming voltage too low incoming voltage to control board. (power low)

F:430 Controller is too cold. 1. Move controller to warmer area. (Temperature too low 2. Add heater to control panel. Limit 1) 3. Consult factory with door serial number.

F:435 The control temperature is too high. 1. Mount the control in a cooler environ- (Temperature too ment. high) 2. Install cooling fan. 3. Consult factory with door serial number.

F:440 Incorrect boost setting, mechanical bind. 1. Check door for mechanical binding. (Over current DC bus 2. Confirm incoming power L1, L2, L3. limit 1) 3. Consult factory with door serial number.

41 SYSTEM PARAMETERS—DRIVE SYSTEM FAULT CODES (500-LEVEL CODES)

DRIVE SYSTEM FAULT CODES (500-LEVEL CODES) Table 14 lists the fault codes associated with the drive system. Included in this table are the available fault codes, a description of each fault code, and the suggested corrective action to clear the fault. NOTE: All 500-level codes are warnings indicating the maximum allowable value has been exceeded. The door will operate only in the failure error jog mode.

Table 14

Fault Code Description Corrective Action (Displayed Message)

F.510 Over current. 1. Check operation of door. (Mtr OC L2) 1. Mechanical problem 2. Check brake. (motor over current 2. Motor brake not releasing 3. Consult factory with door serial number. limit 2) 3. Motor torque boost incorrectly set 4. Motor nameplate parameters (frequency, current, etc.) incorrectly set

F:511 Voltage not going to the motor, may also have 1. Confirm incoming power L1, L2, L3. (No DC Supply) F:519 and 24 V error or over temperature. 2. Consult factory with door serial number.

F:512 Motor not receiving voltage. 1. Confirm incoming voltage L1, L2, L3. (DC bus current 2. Consult factory with door serial number. faulty)

F:513 The brake resistor is defective or missing. 1. Confirm incoming voltage L1, L2, L3. (Brake chopper over 2. Take ohm reading of brake resistor. loaded) Remove wires from terminals X200 and X201. Measure ohms, reading should be 50 ohms. 3. Consult factory with door serial number.

F.515 Maximum motor over current. 1. Check motor: Turn off power, discon- (Mtr OC Ext) 1. Motor or motor connection problem nect motor leads and ground. Ohm wind- (motor over current 2. Incorrect motor parameters ings T1-T2, T2-T3, and T1-T3 readings external) 3. Incorrect motor nameplate parameters should be comparable. Also ohm each motor lead to ground, motor should not ohm to ground. 2. Consult factory with door serial number.

F:518 Motor cable is shorted to ground. 1. Ohm motor windings, T1-T2, T2-T3, (Ground fault recog- and T1-T3 readings should be similar. nized) 2. Ohm T1, T2, T3 to ground. Should have no reading (open line). 3. Consult factory with door serial number.

F.519 IGBT over current. 1. Check motor: Turn off power, discon- (IGBT OC) 1. Faulty motor winding or motor shorted to nect motor leads and ground. Ohm wind- (insulated gate bipolar ground ings T1-T2, T2-T3, and T1-T3 readings transistor over current) 2. Incorrect motor parameters should be comparable. Also ohm each 3. Incorrect motor nameplate parameters motor lead to ground, Motor should not Ohm to ground. 2. Consult factory with door serial number.

42 SYSTEM PARAMETERS—DRIVE SYSTEM FAULT CODES (500-LEVEL CODES)

Fault Code Description Corrective Action (Displayed Message)

F:520 Brake resistor interference, defective, miss- 1. Confirm incoming voltage L1, L2, L3. (Over voltage in DC- ing or feedback voltage from motor is too 2. Take ohm reading of brake resistor. bus Limit 2) high. Remove wires from terminals X200 and X201. Measure ohms; reading should be 50 Ohms. 3. Consult factory with door serial number.

F:521 Motor feeds back too much power, input 1. Confirm incoming voltage L1, L2, L3. (Over voltage DC bus) voltage too low. 2. Take ohm reading of brake resistor. Remove wires from terminals X200 and X201 measure ohms; reading should be 50 Ohms. 3. Consult factory with door serial number.

F:524 Overload on the 24 VDC, NOT a short cir- 1. Reduce 24 VDC devices in use. (External 24 VDC sup- cuit, too much connected to the 24 VDC. 2. Consult factory with door serial number. ply is missing or too low)

F.525 High supply voltage (>+10%). Check incoming voltage. Check parame- (Power OV) Incoming voltage too high ter P:940 = Incoming voltage to control (power over voltage) board.

F:530 Temperature is too low for the controller. 1. Move control to warmer area. (Heat sink tempera- 2. Add heater to control panel. ture outside of work- 3. Consult factory with door serial number. ing range limit 1)

F:535 Temperature inside the control panel is too 1. Move control panel to cooler area. (Housing tempera- high. 2. Install fan inside control panel ture too high) 3. Consult factory with door serial number.

F:540 Motor working too hard, boost not adjusted 1. Verify incoming supply voltage L1, L2, L3. (Over current in DC properly, mechanical bind. 2. Check for mechanical bind. bus limit 2) 3. Check if brake is releasing when attempting to operate. 4. Consult factory with door serial number.

43 SYSTEM PARAMETERS—DOOR POSITION FAULT CODES

DOOR POSITION FAULT CODES Table 15 lists the fault codes associated with the position of the door. Included in this table are the available fault codes, a description of each fault code, and the suggested corrective action to clear the fault. NOTE: The encoder is sensitive to electromagnetic interference (EMI) and many of the F:700 codes are the result of electromagnetic interferences. The encoder cable should be installed in conduit with low voltage wiring.

The encoder cable must be separated from the high-voltage wiring. All cables must be cut to length. DO NOT wrap up excess cable near the motor or in the control panel. P-clip

The encoder shield wire must also be grounded to the P-clip located under the A5400018 System 4 board to capture the encoder cable. DO NOT ground the encoder shield Figure 45 wire to the ground bus on the System 4 board. (See Figure 45.)

Table 15

Fault Code Description Corrective Action (Displayed Message)

F.700 Door limits not set. 1. Set limit P.210. (Pos Sys 1) 1. Set limits 2. Check encoder. (position system 1) 2. Possible encoder failure

F:701 The close limit position was not reached or 1. Recognition time for the switch may be (CLOSE position not found during close. too low P:229. found in timer mode) 2. Check mechanical operation of the motor brake. 3. Consult factory with door serial number.

F:702 The OPEN limit position was not recog- 1. Recognition time for the switch may be (OPEN position not nized during opening. too low P:239. found in timer mode) 2. Check mechanical operation of the motor brake. 3. Consult factory with door serial number.

F:720 Motor may be phased incorrectly, encoder 1. Check encoder for secure and proper (Synchronization not counting properly, door traveled beyond mounting. error in position the limit switches during synchronization. 2. Verify encoder connections and proper sensing with incre- grounding. mental encoder) 3. Consult factory with door serial number. NOTE: May also receive F:030 and F:031 errors in conjunction with F:720.

44 SYSTEM PARAMETERS—DOOR POSITION FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:750 Electrically noisy environment or defective 1. Check encoder wiring connections and (Protocol Transmis- hardware. proper grounding. sion Error) 2. Check motor connections and proper grounding. 3. Consult factory with door serial number.

F:751 Electrically noisy environment or defective 1. Check encoder wiring connections and (Synchronization FUE hardware. proper grounding. absolute encoder) 2. Check motor connections and proper grounding. 3. Consult factory with door serial number.

F.752 Data transmission error. 1. Shielded cable broken, no longer (Protocol 2) 1. Possible electromagnetic interference grounded, or not used where required. (EMI) to control system 2. Check encoder. 2. Encoder problem

F.760 Position of door does not correspond to 1. Shielded cable broken, no longer (Encoder 2) position of encoder. grounded, or not used where required. 1. Possible electromagnetic interference 2. Check encoder. (EMI) to control system 3. Consult factory with door serial number. 2. Encoder or encoder mounting problem 3. Incorrect resolution setting

F:761 The encoder is not counting properly and 1. Check encoder wiring connections and (Distance Channel 1 values are outside the allowed settings. proper grounding. & Channel 2 outside 2. Check motor connections and proper allowed window) grounding. 3. Consult factory with door serial number.

F.762 Limit switches incorrectly set. 1. Limits P.210 reset. 1. Limit settings not valid or properly set 2. Reset limits. 2. Open or partial limit settings out of range 3. Consult factory with door serial number. 3. Control system not initialized

F:763 The controller is not communicating with 1. Check encoder wiring connections and (DES-B error) the encoder or the signals are not being proper grounding. received. 2. Check motor connections and proper grounding. 3. Reset encoder. 4. Consult factory with door serial number.

F:766 Encoder not communicating or counting 1. Check encoder wiring connections and (Internal error TST properly. proper grounding. PD/PE) 2. Check motor connections and proper grounding. 3. Reset encoder. 4. Consult factory with door serial number.

F:767 Temperature of the encoder is too high. 1. Place fan near encoder to lower tem- (Over temperature perature. TST PD) 2. Reset encoder. 3. Consult factory with door serial number.

F.768 The F:768 message appears when the bat- Change battery in the encoder. tery in the encoder needs to be changed.

45 SYSTEM PARAMETERS—WIRELESS SYSTEM FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:769 The encoder hub is turning too fast to prop- 1. Mount encoder to different shaft. (Rotation speed of erly count the increments. 2. Check encoder resolution P:202. the PD shaft is too 3. Consult factory with door serial number. high. PD= Position device)

F.770 Overflow from SSI encoder. 1. The current position of the door com- (Protocol 3) Protocol 3 encoder. pared to the fixed closed position has exceeded the maximal allowed range of 4095 Increments. 2. Set P.202 (used resolution of the encoder) to a higher value and repeat limit setting. 3. Reset P.210 — reset limits. NOTE: Fault F:760 may appear.

WIRELESS SYSTEM FAULT CODES Table 16 lists the fault codes associated with the control system. Included in this table are the available fault codes, a description of each fault code, and the suggested corrective action to clear the fault. Table 16

Fault Code Description Corrective Action (Displayed Message)

F:852 The control panel and the wireless encoder 1. Check encoder wiring connections and (communication error have not communicated for more than 1 proper grounding. between TST FSX and minute. 2. Check motor connections and proper controller) grounding. 3. Check antenna for proper mounting and removal of packing materials. 4. Reset encoder. 5. Consult factory with door serial number.

F:853 The operating voltage of the encoder is too 1. Check encoder wiring connections and (TST PE_FSBS oper- low (less than 8V) and unable to send proper grounding. ating voltage too low) incremental signals. 2. Check motor connections and proper grounding. 3. Reset encoder. 4. Consult factory with door serial number.

F.856 Wireless communication error between sta- 1. Wrong address parametrized. tionary and mobile units. 2. Mobile unit broken. 3. Battery empty. 4. Heavy wireless noise. 5. Stationary antenna broken or mounted wrong.

F.857 Battery low. Reversing edge battery needs to be replaced. Replace with D size lithium ion battery 3.8 volts (Part number 00111193).

46 SYSTEM PARAMETERS—WIRELESS SYSTEM FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:859 The software versions of the stationary and 1. Check encoder wiring connections and (Software Version) mobile units are not compatible. The mobile proper grounding. unit is not communicating with the encoder. 2. Check mobile unit address in the bottom bar and confirm this address is the same as entered in parameter P:F07. 3. Update EPROM or wireless software. 4. Consult factory with door serial number.

F:860 Internal system fault within the wireless 1. Check encoder wiring connections and (Internal fault station- encoder unit. proper grounding. ary unit) 2. Check motor connections and proper grounding. 3. Reset encoder. 4. Consult factory with door serial number.

F:861 Internal system fault on the mobile unit. 1. Check encoder wiring connections and (Internal fault mobile proper grounding. unit) 2. Check motor connections and proper grounding. 3. Check mobile unit connections. 4. Verify mobile unit address matches P:F07. 5. Reset encoder. 4. Consult factory with door serial number.

F:862 Internal error of the encoder positioning 1. Check mechanical mounting of (Internal positioning system, probably a loose encoder hub encoder. system error) magnet. 2. Check that encoder hub is securely attached. 3. Check encoder connections and proper grounding. 4. Reset encoder. 5. Consult factory with door serial number.

F:867 The mobile unit address has not been 1. Check the mobile unit address on the (Address of mobile entered into parameter P:F07. green plastic block of the mobile unit in unit not set) the bottom bar, Verify this is the same number in P:F07. 2. Consult factory with door serial number.

F:900 The controller has not been defaulted to a 1. Consult factory with door serial number. (Internal Error) door type or the default was unsuccessful.

F:910 The controller does not recognize the 1. Check connections of ribbon cables (No communication expansion board. from main power board to expansion to expansion board board. possible) 2. Check the value of P:800. 3. Consult factory with door serial number.

F:911 Controller has the wrong EPROM or 1. Check for proper grounding of supply (ROM Error) EPROM has been swapped from another voltage. board. Too much electrical noise in area or 2. Check proper grounding of wireless control not grounded properly. encoder. 3. Consult factory with door serial number.

47 SYSTEM PARAMETERS—WIRELESS SYSTEM FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:912 Defective hardware or electrical noise. 1. Check for proper grounding of supply (RAM Error) voltage. 2. Check proper grounding of wireless encoder. 3. Consult factory with door serial number.

F:915 Defective hardware, electrical disturbances, 1. Check for proper grounding of supply (Communication or temperature too high. voltage. error between main 2. Check proper grounding of wireless processor and I/O encoder. processor) 3. Unplug and reconnect all ribbon cables on the boards. 4. Consult factory with door serial number.

F:916 Communication with USB stick is not possi- 1. USB stick may need to be reformatted (Error reading USB ble, USB stick is write protected or contains to FAT 32 format. stick) unknown file. 2. Consult factory with door serial number before reformatting.

F:920 Hardware defect. Consult factory with door serial number. (Internal 2.5V reference voltage incorrect)

F:921 Hardware defect. Consult factory with door serial number. (Internal 15V voltage incorrect)

F:922 The E-Stop chain is not complete. There 1. Check E-Stop connections at terminals (E-Stop chain not are 3 E-Stop terminals on the control 240 and 241, 250 and 251, 260 and 261. complete) board: position X24 terminals 240 and 241, 2. If external E-Stop button is used, con- X25 terminals 250 and 251, X26 terminals tact must be normally closed. Verify con- 260 and 261. One of those E-Stop jumpers tact normally closed. is missing or external E-Stop button not 3. Consult factory with door serial number. wired correctly.

F:923 Strong electrical disturbance or defective 1. Check supply voltage L1, L2, L3 for (DC bus voltage mea- hardware. proper grounding. suring is not plausi- 2. Consult factory with door serial number. ble)

F:925 Defective hardware. Consult factory with door serial number. (Testing of the third shutdown method failed.)

F:926 The expected braking current as defined by 1. Check value of P:183. (Bad breaking cur- parameter P:183 was exceeded by more 2. Consult factory with door serial number. rent) than 0.5 amps.

F:927 Door equipped with TLG light curtains are 1. Check wiring for the TLG light curtains. (Faulty testing TLG) tested upon opening; error indicates the 2. Check for proper alignment of the test was unsuccessful. TLGs. 3. Clean the lens of the TLGs. 4. Consult factory with door serial number.

48 SYSTEM PARAMETERS—WIRELESS SYSTEM FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:928 The controller tests the safety and E-Stop 1. Check wire connections of safety (Faulty input testing) inputs each time the door opens; the test devices. was unsuccessful. 2. Check wire connections for the E-Stop inputs. 3. Confirm alignment of photo eyes. 4. Consult factory with door serial number.

F:929 The testing of the stop relay was unsuc- 1. Check wire connections of all E-Stop (Faulty K stop relay) cessful. inputs. 2. Consult factory with door serial number.

F:930 Defective hardware or noisy electrical envi- 1. Check supply voltage L1, L2, L3 for (External watchdog ronment. proper grounding. incorrect) 2. Consult factory with door serial number.

F:931 Wrong EPROM, defective hardware, or 1. Check supply voltage L1, L2, L3 for (ROM error) noisy electrical environment. proper grounding. 2. Consult factory with door serial number.

F:932 Defective hardware. 1. Check supply voltage L1, L2, L3 for (RAM error) proper grounding. 2. Consult factory with door serial number.

F:933 The clock frequency of the processor is 1. Check supply voltage L1, L2, L3 for (Wrong frequency of wrong. proper grounding. CPU) 2. Consult factory with door serial number.

F:934 Error appears on new controllers in the first 1. Allow the controller to perform the RAM (RAM test not ready) 20 seconds after turning ON, before the test. RAM test begins. 2. Do not remove USB stick or cycle power during this message; this will lengthen the test time. 3. Consult factory with door serial number.

F:935 While programming a new controller the Consult factory with door serial number. (Stack error) information is getting repeated, creating a stack error. The controller is unable to process the information.

F:941 The controller is unable to access the ROM Consult factory with door serial number. (ROM error of I/O proof the I/O processor. cessors)

F:942 The controller is unable to access the RAM Consult factory with door serial number. (RAM error of I/O proof the I/O processor. cessors)

F:960 A new EPROM has been installed or the Consult factory with door serial number. (Wrong parameter controller has not been programmed. checksum)

F:961 A new EPROM has been installed or the Consult factory with door serial number. (Checksum from cali- controller has not been programmed. bration values)

49 SYSTEM PARAMETERS—WIRELESS SYSTEM FAULT CODES

Fault Code Description Corrective Action (Displayed Message)

F:962 A new EPROM has been installed or the Consult factory with door serial number. (Converter parame- controller has not been programmed. ters not plausible)

F:963 A new EPROM has been installed or the Consult factory with door serial number. (Ramp parameters controller has not been programmed. not plausible)

F:964 A new EPROM has been installed or the Consult factory with door serial number. (Program version / controller has not been programmed. manufacturer code)

F:965 The door cycle counter doesn't count or is Consult factory with door serial number. (Faulty door cycle faulty. No emergency opening test can be counter with active performed. emergency opening)

F:966 Wrong software was programmed into the Consult factory with door serial number. (Hardware unknown) controller or the programmed software does not know the hardware version.

F:968 The clock program is not plausible. 1. Set clock to current date and time. (Programming error 2. If using clock to run a program, event with real time clock) cycle must be plausible. 3. Consult factory with door serial number.

F:969 The clock has an error. 1. Set clock to current date and time. (Internal error real 2. Consult factory with door serial number. time clock)

F:970 Controller not programmed, new EPROM Consult factory with door serial number. (Plausibility Parame- version and one of the parameters is not ter block error) plausible.

50 MISCELLANEOUS MESSAGES—DELAY TIMERS

DELAY TIMERS Displayed Description Table 17 lists the delay timers associated with the con- Message trol system. Included in this table are the available tim- ▲ ers and their descriptions. Jog Mode ▼ Manual door operation — jog Table 17 mode only. To enter and exit jog mode, push stop and down arrow simultaneously.

Delay Timer Description Locked Closed Door locked in closed position. Input terminal shown in Acl1 = x Sec Auto close delay timer 1. lower right corner of display. (Terminals 210 and 212) Partial Open Door in partial-open Acl2 = x Sec Auto close delay timer 2. Position position. (Terminals 230 and 233) Rytec Door Type Cycle count. Acl3 = x Sec Auto close delay timer 3. (Can be programmed to any Set Limits Start limit set-up procedure. output) SPECIAL STATUS MESSAGES MISCELLANEOUS MESSAGES Table 19 lists the special status messages associated with the control system. Included in this table are the DOOR MESSAGES available displayed messages and a description and Table 18 lists the miscellaneous messages associated definition of each message. with the control system. Included in this table are the Table 19 available displayed messages and a description and definition of each message. Table 18 Displayed Description Message

Displayed Automatic Denotes controller in auto- Description Message matic mode.

Door Held Open Door held open. Input termi- Jog Mode Denotes controller in jog nal shown in lower right of mode. To enter and exit jog display. mode, push stop and down arrow simultaneously. Door Is Closing Door is closing.

Door Is Open Door open in full-open posi- DOOR LIMIT MESSAGES tion. Table 20 lists the door limit messages associated with the control system. Included in this table are the dis- Door Is Opening Door is opening. played messages and a description of each message. Door Is Stopped Door is stopped — controller Table 20 waiting for next incoming command. Displayed Message Description Emergency Jog Door travel possible in jog mode only — all safety and ! Set Limits ! Limit set-up initialization. limits ignored. → ● To Begin Initialize limit setting. Emergency Stop One of the emergency stops is activated. →Ú To Closed Pos. Close limit set-up.

▲ Error Jog ▼ Only Door fault — door travel in jog →Ú To Open Pos. Open limit set-up. mode only. →Ú To Part. Pos. Partial limit set-up.

51 MISCELLANEOUS MESSAGES—DOOR JOG MESSAGES

Displayed Message Description Displayed Message Description

Close Limit Set Close limit setting. I.100 Open Spd. Excessive door speed (check open speed) near full-open position. ● Hold If Ok Save limit setting. Open speed is too high; Open Limit Set Open limit setting. check P:310 opening speed in Hertz. Part. Limit Set Partial limit setting. I.150 Close Spd. Excessive door speed (check close speed) near full-closed position. DOOR JOG MESSAGES Closing speed too high; Table 21 lists the door jog messages associated with the check P:350 closing control system. Included in this table are the displayed speed in Hertz. messages and a description of each message. I.160 Close Req. Continuous OPEN still Table 21 (close requested) active. Close requested; however, door is still receiving an Displayed Message Description open command. Look for activator sending open Bynd Opn P. Door jogged past full- signal(s) request. For (beyond open position) open position. example, a stuck pull cord Jogg. Close Jogging door closed with (not releasing). (jog close) down (▼) key. I:161 Priority not Inputs can be prioritized. Door Is Opn Door jogged fully open, active For instance, if loop is (door is open) additional door open active and the down arrow travel not possible. was pushed, a close command is sent to the con- Door Is Cls Door jogged fully closed, troller; however, the door (door is closed) additional door close remains open because the travel not possible. loop is the priority input. Message I:161 will be Jogg. Open Jogging door open with present when arrow is (jog open) (▲) key. pushed and the loop is active. DOOR STATUS MESSAGES I.170 Timed Open Forced opening being per- Table 22 below lists door status messages associated (timed open) formed. This is performed with the control system. Included in this table are the with parameter P:018. The displayed messages and a description of each mes- value is in minutes and the sage. factory setting is 0. Enter- Table 22 ing a value will cause the door to open when the time is reached. This fea- Displayed Message Description ture is often used in freezer door applications. I.060 Self repair after door ajar in progress.

I.080 Maintenance required soon — service counter nearly expired.

52 MISCELLANEOUS MESSAGES—DOOR STATUS MESSAGES

Displayed Message Description Displayed Message Description

I:180 Waiting for key- Control of the door is per- I:200 Reference posi- This message may appear pad command formed through the key- tion corrected or rec- after the door has finished pad of the control panel or ognized calibrating. The door has selected inputs are pro- recognized the door is grammed to function simi- traveling differently and is lar to the keypad. An trying to adjust to the new example may be a guard position. If message con- shack. The guard controls tinues to appear, check the door from the guard encoder mounting and shack; therefore, the I:180 grounding of encoder message may appear drain wire. The error code when the door is waiting to F:030 Motor Stall will likely close. appear shortly after the I:200 message. I:185 Wait for reset by The controller is waiting to stop keypad. be reset by the reset but- I.300 Air Locked Locked by another door. ton on the keypad. This (air locked) can also be performed remotely by programming I.310 Open A12 Door open command an input to perform as the (open A12) initiated to other door in air keypad reset on the con- lock. trol panel. I.400 HD Limit Hard door not open. I:186 The controller This message appears (freezer only) In freezer applications, will shut down after a after a 3 finger reset. A 3 Rytec sends additional user reset (3 finger finger reset is when all 3 switches that turn the reset) buttons (open, stop, and defrost heaters OFF if an close) are pushed and insulated door is used on held simultaneously. The site. The switches acti- controller does a shut- vate and deactivate the down and automatically defrost system. The elec- resets. Additional mes- trical schematic states if sages will be displayed as the switches are not used, the controller resets. Allow jumper wires must be the controller to reset. DO installed for the defrost to NOT interrupt the reset operate. If the jumpers are process. This may take 3– not installed, the informa- 5 minutes to reset. This tional message "I:400 HD reset doesn't change or Limit" and “I:401 Defrost alter any of the parameter Off" will be displayed on settings. This process is the screen. similar to turning the power OFF and ON.

I.199 Counter Err Door cycle counter error. (counter error)

53 MISCELLANEOUS MESSAGES—DOOR STATUS MESSAGES

Displayed Message Description Displayed Message Description

I.401 Defrost Off Defrost deactivated. I.520 Maximum speed during (freezer only) In freezer applications, automatic limit switch cor- Rytec sends additional rection is not reached. switches that turn the defrost heaters OFF if an I.555 Auto Calibration Limit switches being cor- insulated door is used on rected. site. The switches acti- I:901 Wait for USB The USB stick is initializ- vate and deactivate the stick ing; allow the message to defrost system. The elec- clear before beginning. trical schematic states if the switches are not used, I:902 Update file not The controller was told to jumpers wires must be found on USB stick download the new files off installed for the defrost to the USB stick; however, operate. If the jumpers the USB contains no new are not installed, the infor- files. mational message "I:400 HD Limit" and “I:401 I:903 Cannot open The controller recognizes Defrost Off" will be dis- file a new file is present; how- played on the screen. ever, file format or type is incorrect. I.510 Auto Calibration Limit switch correction finished. I:904 Deleting ROM The controller has been The 500-level messages told to delete the ROM. appear on the screen after I:905 Programming The controller has been the door limits have been ROM told to program the ROM. set. DO NOT make any corrections to the speeds I:906 Update file has Controller recognizes a or limits while the 500- the wrong format. new file is present but is level messages are pres- unable to read the file due ent on the screen. to incorrect file or format. NOTE: The door may stop short of the close position I:908 RS485 encoder The encoder connected and speed up and slow interface via RS485 connection. down during the 500 mes- I:915 Testing Suc- The controller performs a sages; this is normal. Con- cessful test of the entire system, tinue operating the door and the test was success- until the 500-level mes- ful. sages leave the screen. During the 500-level mes- I:916 Error reading The controller tried to read sages, the controller is USB stick the data stored on the self-learning the optimum USB stick but is unable to run curve for the door. read because file format is After the 500-level mes- incorrect or the USB stick sages leave the screen, is write protected or full of you can then make correc- data. tions to the limits if necessary. I:917 Log function is The controller is reading This message is for all being initialized and writing information to 500-level messages. the USB stick and places the door in an idle mode I.515 Auto Calibration Controller is preparing until this process is com- automatic teach-in of the pleted. limit switches.

54 MISCELLANEOUS MESSAGES

Displayed Message Description Text Message Description Number I:927 TLG testing not The controller tests for the successful presence of the TLG light 6 (Stop) Stop door. curtains. this message (Normally closed: remove appears if the test is jumper terminals 200 and unsuccessful. TLG wired 203) incorrectly, dirty, or out of alignment. Only used for 7 (Photoeye — Fr) Front photo eye. Effaflex TLG light curtains. (Terminal 222)

I:928 No TLG testing Controller knows the TLGs 8 (Photoeye — Rr) Rear photo eye. done are connected to the con- (Terminal 232) troller, but the testing pro- 9 (Photoeye — Aux) Auxiliary photo eye. cess has been turned OFF. 10 (Door Ajar) Breakaway bottom bar disconnected from side I:940's ALL 940-94F The controller may dis- column. (Terminal 271) ERRORS in relation play a number of the I:940 to parameter files messages. The I:940 mes- 11 (Blower On) Freezer blower on. sages indicate either the parameter file cannot be 12 (Blower High) Freezer blower on high. loaded due to wrong type 13 (Blower Auto) Freezer blower on auto. of file, write protected, storage is full, content is 14 (Heater St.1) Freezer heater stage 1 or not valid in the parameter heat lamps on. file, or of unknown error. 15 (Heater St.2) Freezer heater stage 2 on.

PROGRAMMABLE TEXT MESSAGES 16 (Heater St.3) Freezer heater stage 3 on.

Table 25 lists the programmable text messages associ- 17 (Heater Auto) Freezer heater on auto. ated with each input of the control system. Included in this table are the available text messages and their 18 (HW Interlock) Freezer hard door interlock. description. 19 (Jog Mode) "Jog Mode" displayed on Table 23 screen.

20 (permanent “Permanent Open” displayed Text Message open) on screen. Description Number 21 (crossing traf- “Crossing traffic” displayed 1 (Open) Open door. fic) on screen. (Terminals 200 and 201) 22 (Deactivation) “Deactivation” displayed on 2 (Open — ACL1) Open/close with ACL1 timer. screen. (Terminals 210 and 212) 23 (reference “Reference switch” displayed 3 (Open — ACL2) Open/close with ACL2 timer. switch) on screen. (Terminals 230 and 233) 24 (Clean Mode) “Clean Mode” displayed on 4 (A/A Op — C1) Door open and close. screen. (Terminals 210 and 211) 25 (Locked Close) “Locked Close” displayed on 5 (Close) Close door. screen. (Terminals 200 and 202) 26 (Beam Blocked) “Beam Blocked” displayed on screen.

27 (Beam Error) “Beam Error” displayed on screen.

55 TROUBLESHOOTING—TROUBLESHOOTING WITH STATUS LEDS

Table 24 Text Message Description Number Associated LED LED Group 52 (Safety Edge) “Safety Edge” displayed on Function screen. Emergency Stop NOTE: Reference 56 (Deactivation “Deactivation intermediate Chain LEDs Figure 46 for intermediate stop) stop” displayed on screen. LED location. TROUBLESHOOTING 1 = E-Stop 1 TROUBLESHOOTING WITH STATUS LEDS First External E-Stop 2 = E-Stop 2 If a problem occurs with the control system or the door, Second External E-Stop the controller is configured with various light-emitting 3 = E-Stop 3 diodes (LEDs) that can be helpful when troubleshooting Third External E-Stop the problem. The LEDs are grouped in various functions and indicators as detailed in Figure 46. Table 24 details Note: LEDs E-Stop 1, 2, the interpretation of each group of LEDs. and 3 must all be on for normal operation.

Input LEDs (LEDs on = contact connection closed 24V Short LED LEDs off = contact connection open)

Reversing Edge Normal operation = red is LEDs (Green and red) OFF and green is ON. 0 ohms (short) = red and green are both OFF. Green Infinite ohms (open) = Reversing both red and green LEDs Red Edge LEDs Run LEDs are ON. (Green) 24 V Short LED Normal operation = LED off Red in color 24 V failure = LED on Note: See Figure 41 for 24 VDC system short = Ajar LED clear bulb on main flashing LED board, which also Note: If the 24 V power E-Stop 3 lights when 24 VDC supply is overloaded or E-Stop 2 short. Both will light has a defective device when 24 VDC is (such as a shorted photo Input LEDs E-Stop 1 shorted. eye) connected to it, the A5400016 power supply will automatically power down for Figure 46 self-protection.

Run LED There are two green LED’s. The left one flashes with the speed of the door (power to micro- board). The other flashes at a constant rate (power to main board).

56 SPECIFICATIONS—MECHANICAL

SPECIFICATIONS MECHANICAL Table 25

Enclosure Black plastic w/semi-transparent cover window Dimension L x W x H (approx.) 16 ³/₄ x 8 ¹/₄ x 7 ³/₄ inches (425 x 210 x 195 mm) • includes heat sink, brake resistor, and wall brackets • excludes cable glands, optional switches, and circuit breakers Materials Polycarbonate Macrolon (no silicone) Heat Sink Aluminum (natural)

Board Dimension Approx. 10.5 x 8 x 5.5 inches (270 x 200 x 140 mm)

Mounting Brackets Wall brackets integrated in bottom side of enclosure Vertical installation only

Weight Approx. 11 lb. (5 kg)

Protection Class/Rating TST FU3R-A: UL Type-4X Standard Enclosure TST FU3R-AP: open type (Pollution Degree 2 environment only)

Operating Temperature Range: Enclosed type/open type (vertically mounted) Ambient –4 to 122/149°F (–20 to 50/65°C) at 50% duty cycle of max. motor load –4 to 113/140°F (–20 to 45/50°C) at 83% duty cycle of max. motor load –4 to 104/131°F (–20 to 40/55°C) at 100% duty cycle of max. motor load Storage –13 to 158°F (–25 to 70°C)

Relative Humidity Up to 80% (non-condensing)

Vibration Low vibration installation, e.g., on a concrete wall

Conduit Entry Formed plastic conduit bosses (appropriately sized holes for conduit must be drilled in boss locations)

Internal Power Consumption Max. 50 W Fully assembled controller w/o running motor

Approval UL-listed power conversion equipment for USA and Canada Inverter control: UL 508C 24 V power supply output: Class 2

Marks/Stickers TST FU3-AP: UL/UR sticker and serial number TST FU3P-A: UL sticker, serial number “WARNING High Voltage” provided by Rytec.

Clock 24-hour real-time clock with integrated gregorian calendar 4-channel electronic timer Accuracy limit: Max. 5 sec/day over full temperature range

Battery Socket prepared for lithium coin cell CR2032 (3 V)

57 SPECIFICATIONS—INPUTS

INPUTS Table 26

Power Supply (Line Voltage) Standard 185–500 volt, single- or three-phase External Fuse: 20 amp, class CC

Emergency Stop/Safety Chain All inputs have to be connected potential free (E-Stop 1, 2, and 3) Contact ratings: 0 to 26 VDC and 10 to 200 mA <5V: inactive Jlogical 0 >7V: active Jlogical 1 Indicated by individual LEDs When safety chain is interrupted, no movement of the drive is possible, not even in jog mode. Factory Setting: Jumpered as in TST FU3P-A

Standard Inputs (IN1–IN10) 24 VDC / typ. 15 mA, max. 26 VDC / 20 mA Inputs 2 and 3 are dedicated photo All inputs have to be connected potential free or: eye inputs and require that only spe- <5V: inactive Jlogical 0 cific photo eye connections are made >7V: active Jlogical 1 to these two specific inputs. No other Indicated by individual LEDs electrical connection should be made Min. signal duration for input control commands: > 100 ms to these two photo eye inputs or power source.

Input for Safety Edge For electrical safety edges with 1.2K ohm or 8.2K ohm resistance evaluation and for dynamic optical systems. 3 status conditions are indicated by LEDs: 0 ohms (short), 1.2/8.2K ohms, infinite ohms (open).

Keypad 24 VDC/typ. 15 mA 3 Button: Common connected to 24 V, 5-pole connector, ¹/₁₀ reference grid 2 LED Outputs: 24 VDC/max. 20 mA LED only Short and overload protection Mainly prepared for flashing light on keyboard

Inputs INK1 and INK2 24 VDC/max. 20 mA load (Alternative: digital control inputs IN11 <5 V: inactiveJlogical 0, >16 V: activeJlogical 1 indicated by individual and IN12) LEDs Incremental encoder specification: • Maximum frequency 1 kHz • 90° offset between both input signals

Serial Interfaces Asynchronous bidirectional serial interface for electronic limit switches, RS485 A and B wireless safety equipment, and other special equipment from RS485 level, terminated with 100 ohms

USB Host For USB-Memory stick w/PC compatible file organization (USB profile “Mass Storage”, Sub Class Code “SCSI Transparent Command Set” (6), Interface Protocol “Bulk Only Transfer” (5), Logical Unit Number (LUN 0), no hubs possible Connector: Type A Max. Supply: 100 mA Max. Cable Length: 7 ft. (2 m) Alternative USB Device For PC communication with protocol (service only) (communication devices simulate virtual serial port) Connector: Type B Max. Cable Length: 7 ft. (2 m)

58 SPECIFICATIONS—OUTPUTS

Interface Bus I TTL communication line For internal mounted I/O expansion board TST RFUxK only Max. Distance: 4 in. (10 cm)

Interface Bus II TTL communication interface to interface converter board TST RFUxCom for communication with external mounted I/O expansion board TST RFUxK Max. Distance: 100 ft. (30 m)

Interface Bus III TTL communication interface to interface converter board TST RFUxCom for communication with a second prepared door controller TST FURR Max. Distance: 100 ft. (30 m)

OUTPUTS Table 27

Supply Output I Nominal value: 24 VDC ± 5% Max. Load: 3.5 A (includes brake, all plug-in modules, expansion boards, and supply output II, etc.) Overload protected by self-resetting semiconductor fuse Short circuit protected by central switching regulator (switch off the complete control system supply)

Supply Output II (Part of Supply Output For electronic limit switches and safety edge evaluation I) Nominal value 11.3 V/max. 250 mA Overload protected, short circuit proof, and self-resetting

Motor/Drive Output 3 hp motor (derating for single phase supply) 5 Amps @ 480 V service voltage 10 Amps @ 230 V service voltage Overload: 20 A for 0.5 seconds (motor overload protection is provided) Max. Length of Motor Cable: 100 ft. (30 m) Shielded cable is required; motor lines have to be separated from any other wires. A separate motor contactor is NOT provided. ATTENTION: High voltage on output terminals is also possible in E-STOP mode.

Brake Output 24 VDC/2.5 A (supplied by internal power) Electrical switch (e.g, transistor based) 2-pole plugable terminal Short and overload protected Prepared for SEW brake BMG4T, 40 Nm, 56 AC/24 DC Additional noise suppression on electromechanical brake required (e.g, RC)

Auxiliary Relays Outputs Change over contact elements 250 V permitted only when con- (115 V is more important than pluga- Potential free necting the same phase as the sup- ble terminals) 250 VAC/¹/₃ hp ply voltage. Contacts used once for 30 VDC/max. 10A/min. 10 mA power switching (>100 mA) can no Pilot duty B300, R300 longer switch low currents.

Brake Resistance Load Max. 2 hp (1.5 kW) for max. 0.5 seconds Repetition rate min. every 20 seconds Brake resistor is mounted on the heat sink

Relay Outputs If inductive loads are switched (e.g., additional relays), they must be equipped with recovery diodes and appropriate noise suppression means (e.g, regenerate diodes, varistors, RC elements) Be careful in switching capacitive loads as they are often in external power supplies or LED lights.

59 SPECIFICATIONS—PLUG-IN MODULES (OPTIONAL ITEMS)

Test Signal Output 24 VDC/min. 10 mA/max. 100 mA Resistance load only Short and overload protected Mainly prepared for test inputs on photo eyes

PLUG-IN MODULES (OPTIONAL ITEMS) Table 28

Plug-In Modules TST SFSS: 2-channel radio receiver module TST SUVEK: 2-channel induction loop detector module w/terminals on board (alternative TST SUKS—second resistor evaluation or other safety equipment)

Expansion Board TST RFUxK TST RFU3P (Freezer) is NOT provided

Communication Board TST RFUxCOM

Display Direction Board TST RLCCDR-A

Wireless Safety Edge 2.4 to 2.485 GHz, using frequency hopping N.O. (normally open) switch with 8.2K-ohm resistor located in the door bottom bar

ABBREVIATIONS Unit Abbreviation Table 29 lists the abbreviation of each unit of measure- ment referenced throughout the control system program Percentage % menu and this manual. Seconds Sec Table 29 Voltage (Volt) V

Unit Abbreviation Alternating Cur- VAC rent Voltage Celsius °C Direct Current VDC Counter Cnt Voltage

Current (Ampere) A

Cycles Cyc

Digits Dig

Fahrenheit °F

Gigahertz GHz

Hertz (Frequency) Hz

Horsepower hp

Increments Inc

Milliampere mA

Megahertz MHz

Milliseconds Ms

Minute Min

Number #

60 SCHEMATICS—GENERAL — INCOMING POWER

SCHEMATICS GENERAL — INCOMING POWER

NOTE: This schematic is provided for general information purposes only. Due to varying requirements for individual installations, another schematic is shipped with each door and that schematic must be used for that specific installation. NOTE: Dashed lines indicate additional field wiring may be required. Incoming Power

A5400025

Figure 47

61 SCHEMATICS—GENERAL — ENCODER AND PHOTO EYES

GENERAL — ENCODER AND PHOTO EYES

NOTE: This schematic is provided for NOTE: Dashed lines indicate general information purposes additional field wiring only. Due to varying require- may be required. ments for individual installations, another schematic is shipped with each door and that schematic must be used for that specific installation. Rear Photo Eye Connections Rear Photo Eye Remote Activation RemoteConnections Activation Front Photo Eye Connections Photo Eye Front BarEncoder Connections and Bottom

A5400026

Figure 48

62 SCHEMATICS—GENERAL — RADIO CONTROL AND E-STOP

GENERAL — RADIO CONTROL AND E-STOP

NOTE: This schematic is provided for NOTE: Dashed lines indicate general information purposes additional field wiring only. Due to varying require- may be required. ments for individual installations, another schematic is shipped with each door and that schematic must be used for that specific installation. n Connection (Optional) Radio Control Connections Open, Close, Stop Statio Stop Open, Close, Loop Detector Connections Remote Emergency Stop Connections (Optional)

A5400027

Figure 49

63 SCHEMATICS—GENERAL — BOTTOM BAR CONNECTIONS

GENERAL — BOTTOM BAR CONNECTIONS

NOTE: This schematic is provided for NOTE: Dashed lines indicate general information purposes additional field wiring only. Due to varying require- may be required. ments for individual installations, another schematic is shipped with each door and that schematic must be used for that specific installation. Activation Connections, Motion, PC, PB, Etc. PB, Connections, Motion, PC, Activation Equipment) (Optional Encoder and Bottom Bar Connections

A5400028 Figure 50

64 SCHEMATICS—GENERAL — CONTROLLER DIMENSIONS

GENERAL — CONTROLLER DIMENSIONS

NOTE: This schematic is provided for general information purposes only. Due to varying requirements for individual installations, 8.25 another schematic is shipped with each door and that schematic must be used for that specific installation.

16.75

A5400011 Figure 51

65 PARTS LIST—PARTS ORDERING INFORMATION

PARTS LIST Substitute Parts PARTS ORDERING INFORMATION Due to special engineering or product enhancement, the actual parts used on your control system may be How to Order Parts different from those shown in this manual.

1. Identify the parts required by referring to the follow- If a part has been improved in design and bears a ing pages for part numbers and part descriptions. revised part number, the improved part will be substi- tuted for the original part ordered. 2. To place an order, contact your local Rytec representative or the Rytec Technical Support Depart- Return of Parts ment at 800-628-1909 or 262-677-2058 (fax). Rytec will not accept the return of any parts unless they 3. To ensure that the correct parts for your controller are accompanied by a Return Merchandise Authoriza- are shipped, please include the serial number of tion (RMA) and incident numbers form. your door with the order. Refer to the owner’s man- Before returning any parts, you must first contact the ual of your door to determine the location of the Rytec Technical Support Department to obtain authori- serial number plate. The serial number plate is gen- zation and an RMA and incident numbers form. erally located inside one of the side columns. NOTE: You must provide the door serial number (See Figure 52.) for all control panels and enclosures. The SERIAL NUMBER(S) door serial number can be found on a Yo u r DOOR SERIAL NUMBER information can be white decal inside the control panel door. found in three universal locations. These are at the inside of either side column (approximately eye level), on the drive motor, and on the inside door of the System 4 control panel.

IMPORTANT: When installing multiple doors of the same model but in different sizes, verify the serial number in the control panel with the one on the door assembly.

Rytec System 4 Control Panel

Left Side Column (Includes Counterweight

Right Side Column (Includes Counterweight A2500264 Figure 52

66 NOTES

CONTROL PANEL — STANDARD PANEL

A5400036

Figure 53

ITEM QTY. PART # DESCRIPTION

1 1 Consult Factory System 4 Control Panel Assembly, 200–500 V 2 1 00122000 Loop Module 3 1 0012161 Radio Control Receiver 4 1 00111193 Battery, D w/tabs

67 NOTES